Not A Crane

Copyright
SECTION INDEX
HYDRAULICS
Section Title Section Number
Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001

Hydraulic Specifications, Troubleshooting, and Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002
Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8004
Loader Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8005
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006
Coupler Solenoid Locking Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007
Ride Control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013
Ride Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8014
Copyright 2007 CNH Italia S.p.A.

CNH Italia S.p.A. All rights reserved.
Viale delle Nazioni, 55
41100 Modena Printed in E.C.
Italia 87551879A Issued January, 2007
Copyright
Copyright
8001
Section
8001
REMOVAL AND INSTALLATION OF HYDRAULIC

COMPONENTS

Copyright
8001-2
TABLE OF CONTENTS
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Loader Control Valve Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Joystick and 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
BUCKET CYLINDERS - XT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
XT Loader Bucket Cylinder Removal And Installation Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
87551879A Issued 1-07 Printed in E.C.

Copyright
8001-3
LOADER CONTROL VALVE
Removal STEP 5
STEP 1
Park the machine on a level surface.
IMPORTANT: If machine is equipped with
quick-attached components, disconnect them from
machine prior to proceeding.
STEP 2
BD06H198
Relieve the pressure in the ride control accumulator

with the manual bleeder valve located on the top of
the ride control valve. Remove the plug and turn the
valve two turns counter-clockwise.
STEP 6
Loosen the filler cap on the reservoir to release the
air pressure in the reservoir.
BD03A092
STEP 7
Raise the lift arms and install the safety link on the lift
arm cylinder. Drain the hydraulic reservoir.
STEP 3 STEP 8
Stop the engine and apply the parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.
STEP 4
Place the master disconnect switch in the OFF
position.
BD03A093
Loosen and remove the bolts and washers that

fasten the access cover plate for the loader control
valve. Remove the cover plate.

Copyright
8001-4
REAR OF MACHINE
6
7
5
3
1
2 4
BC05M094
1. GREEN WHITE GREEN 4. ORANGE BLACK GREEN 7. GREEN BLACK GREEN

2. RED WHITE GREEN 5. GREEN WHITE GREEN 8. RED BLACK GREEN
3. YELLOW BLACK GREEN 6. RED WHITE GREEN 9.
HYDRAULIC VALVE PILOT LINE CONNECTIONS

Copyright
8001-5
1 2
3
4
6 7
BC05M093
1. DUMP LINE 4. RAISE LINE RIGHT 6. LOWER LINE RIGHT

2. ROLLBACK LINE 5. LOADER VALVE 7. RAISE LINE LEFT
3. LOWER LINE LEFT
LOADER CONTROL VALVE LINE CONNECTIONS

Copyright
8001-6
STEP 9 Installation
Disconnect the hoses (3, 4, 7, 8 if equipped 1, 2, 5,
IMPORTANT: Before installing the fittings or
and 6) from the remote control valve(s) at the loader
connecting the tubes to the fittings, install new
control valve. Refer to the illustration on page 4 for
O-rings on the fittings.
color coding. Install a plug in each hose and a cap on
each fitting.
STEP 16
NOTE: Line 1, 2, 5, and 6 will need to be tagged as
right or left of valve.
STEP 10
Loosen and remove tilt cylinder lines (1 and 2). Install
a plug in each line and a cap on each fitting.
STEP 11
Loosen and remove lines (3 and 4). Install a plug in
each line and a cap on each fitting.
STEP 12 BC05M096
Loosen and remove lines (6 and 7). Install a plug in Install and align the loader control valve with the
each line and a cap on each fitting. valve mounting plate.
STEP 13 STEP 17
Loosen and remove supply and return lines. Install a Install the bolts and washers that fasten the loader
plug in each line and a cap on each fitting. control valve to the valve mounting plate. Tighten the
bolts.
STEP 14
Attach proper lifting equipment to lift loader control STEP 18
valve. Tighten the left lift cylinder lines (6 and 7).
STEP 15 STEP 19
Install and tighten the supply and return lines.
STEP 20
Install and tighten right lift cylinder lines (3 and 4).
STEP 21
Install and tighten tilt cylinder lines (1 and 2).
STEP 22
Connect the hoses (3, 4, 7, 8 if equipped 1, 2, 5, and
6) to the remote control valve(s) at the loader control
BC05M096
valve. Refer to the illustration on page 4 for color
Loosen and remove the three bolts and washers that
coding.
hold the loader control valve to the valve mounting
plate. Remove the loader control valve.

Copyright
8001-7
STEP 23 STEP 27
Fill the hydraulic reservoir with oil. Refer to Section Run engine at half throttle.
1002 for the correct oil.
STEP 28
STEP 24 Slowly and completely extend and retract all
Tighten the accumulator manual bleeder valve cylinders at least 10 times to remove any air from the
located on the top of the ride control valve to a torque circuits.
of 3.5 Nm (31 lb-in). Install the plug and torque to
7 Nm (62 lb-in). STEP 29
Stop the engine and check for leaks.
STEP 25
Place the master disconnect switch in the ON STEP 30
position. Install the access cover on the front of the machine.
STEP 26 STEP 31
Check the level of the hydraulic oil and add hydraulic
oil as required.
BD03A092
Raise the loader arms and remove the safety link.

Copyright
8001-8
REMOTE CONTROL VALVE
Removal STEP 37
STEP 32
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
circuit, turn ignition switch OFF. BD06F208
Open and remove the access panel.

STEP 33
Place the master disconnect switch in the OFF STEP 38
position.
STEP 34
Unlatch and open the right hand side access door.
STEP 35
Lift the access door up and remove the access door
from the pins.
STEP 36
BD06F209
Remove the front access panel.
STEP 39
BD06F207
Unlatch and open the window on the right hand side.
BD06F210
Disconnect the electrical connectors for the remote

control valve.
STEP 40
Loosen the filler cap on the reservoir to release any
air in the reservoir. Connect a vacuum pump to the
hydraulic reservoir, turn on the pump.

Copyright
8001-9
STEP 41 Installation
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install STEP 45
plugs in the hoses and caps on the fittings. Install new O-rings on the adapters for the remote
control valve.
STEP 42
Loosen and remove the screws and washers holding STEP 46
the hydraulic control tower cover. Remove the cover. Install the remote control valve and screws in the
hydraulic control tower and tighten the screws.
STEP 43
Loosen and remove the screws that fasten the STEP 47
remote control valve to the hydraulic control tower. Install the cover over the remote control valve and
install the screws and washers.
STEP 44
Remove the remote control valve from the hydraulic STEP 48
control tower. Remove the plugs from the hoses and the caps from
the fittings and connect the hydraulic hoses to the
fittings according to the identification tags. (Refer to
illustrations on pages 11, 12, and 13 as necessary.
STEP 49
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 50
BD06F210
Connect the electrical connectors for the remote

control valve.
STEP 51
Place the master disconnect switch in the ON
position.
STEP 52
Start the engine and run the engine at low idle.
STEP 53
Check to see that the remote control valve works
correctly.

Copyright
8001-10
STEP 54 STEP 57
Check for hydraulic oil leakage at the remote control
valve.
STEP 55
Check the level of hydraulic oil in the reservoir and
add as required.
STEP 56
BD06F208
Install and close the access panel.
STEP 58
BD06F209
Position the access panel on the ROPS cab or the

ROPS canopy and install and tighten the screw.
BD06F207
Close the right hand window.

Copyright
8001-11
3
8
6
7
1
5
7 8
7 5
1 2
8 3
6 4
BC05M092
1. PILOT TANK HOSE 4. ORANGE BLACK GREEN 7. GREEN WHITE GREEN

2. PILOT PRESSURE HOSE 5. GREEN BLACK GREEN 8. RED WHITE GREEN
3. YELLOW BLACK GREEN 6. RED BLACK GREEN
JOYSTICK AND 2 LEVER HOSE COLOR CODING

Copyright
8001-12
5 5
7 1 4 7
3
4
6 3
2 1
6
2
7 7
7 7
1 1
2 2
6 6
3 3
4 5 4 5
BC05M091
1. PILOT TANK HOSE 1. PILOT TANK HOSE

2. PILOT PRESSURE HOSE 2. PILOT PRESSURE HOSE
3. RED BLACK GREEN 3. RED BLACK GREEN
4. ORANGE BLACK GREEN 4. ORANGE BLACK GREEN
5. YELLOW BLACK GREEN 5. YELLOW BLACK GREEN
6. GREEN BLACK GREEN 6. GREEN BLACK GREEN
7. RED WHITE GREEN 7. RED WHITE GREEN
3 LEVER HOSE COLOR CODING JOYSTICK AND 1 LEVER HOSE COLOR CODING

Copyright
8001-13
1
5
4 5 4 6
6 3 2
3 1
2
2 1 2 1
6 6
3 3
4 5 4 5
BC05M090
1. PILOT TANK HOSE 1. PILOT TANK HOSE

2. PILOT PRESSURE HOSE 2. PILOT PRESSURE HOSE
3. RED BLACK GREEN 3. RED BLACK GREEN
4. ORANGE BLACK GREEN 4. ORANGE BLACK GREEN
5. YELLOW BLACK GREEN 5. YELLOW BLACK GREEN
6. GREEN BLACK GREEN 6. GREEN BLACK GREEN
2 LEVER HOSE COLOR CODING JOYSTICK HOSE COLOR CODING

Copyright
8001-14
HYDRAULIC PUMP
10
7 15
4
6
4
16
5
8 15
6
2 13
3
14
11
9
12
BC05M095
1. PUMP MAIN HYDRAULIC 5. SPLIT FLANGE 9. STEERING HIGH PRESSURE 13. LOADER HIGH PRESSURE
2. MOUNT BOLTS 6. TUBE 10. CLAMPS 14. STEERING PRIORITY MANIFOLD
3. DRAIN HOSE 7. HOSE SUCTION 11. STEERING LOAD SENSE HOSE 15. CLAMPS
4. BOLT 8. HOSE CASE DRAIN 12. LOADER LOAD SENSE HOSE 16. FITTINGS

Copyright
8001-15
Removal STEP 69
Connect lifting equipment to hydraulic pump (1).
NOTE: When disconnecting hydraulic fittings, plug
Take up all slack in lifting equipment. Remove four
hoses and cap fittings to prevent entry of foreign
mounting bolts (2) and washers securing pump to
matter into hydraulic system.
transmission. Pull hydraulic pump from transmission
and remove from loader. Remove and discard O-ring
STEP 59 from pump.
bucket to the floor. Stop the engine and apply the Installation
parking brake.
NOTE: Install new O-rings where required.
STEP 60
Place the master disconnect switch in the OFF STEP 70
position. Install new O-ring on hydraulic pump flange. Move
pump into position and install in transmission. Install
STEP 61 four washers and bolts (2) to secure pump (1) to
Loosen the filler cap on the reservoir to release any transmission, tighten the bolts. Disconnect lifting
air in the reservoir. Connect a vacuum pump to the equipment from pump.
hydraulic reservoir, turn on the pump.
STEP 71
STEP 62 Connect pump pressure hoses (9 and 13) to steering
Refer to Section 9007 and remove the ROPS cab or priority manifold (14).
ROPS canopy.
STEP 72
STEP 63 Connect drain hose (3).
Remove eight bolts (4) and washers. Remove four
split flanges (5). Disconnect tubes (6) with suction STEP 73
hoses (7) from hydraulic pump. Remove and discard Connect load sense hoses (11 and 12).
O-ring face seals from flange heads of tubes.
STEP 74
STEP 64 Install and connect case drain hoses (8).
Loosen clamps (10). Tag and disconnect suction
hoses (7) from hydraulic reservoir and remove from STEP 75
machine. Install suction hoses (7), tighten clamps (10) to 10 to
11 Nm (90 to 100 pound inches).
STEP 65
Tag and disconnect case drain hoses (8) from fittings STEP 76
(16); remove hoses (8). Remove and discard O-ring Install four split flanges (5). Install eight bolts (4) and
face seals from fittings. washers, tighten bolts (4) to 73 to 90 Nm (53.8 to
66.3 pound feet).
STEP 66
Tag and disconnect load sense hoses (11 and 12). STEP 77
Remove and discard O-ring face seals from fittings. Refer to Section 9007 and install the ROPS cab or
ROPS canopy.
STEP 67
Tag and disconnect drain hose (3). Remove and STEP 78
discard O-ring face seals from fittings. Turn off the vacuum pump and disconnect from the
STEP 68
Tag and disconnect pump pressure hoses (9 and 13) STEP 79
from steering priority manifold (14). Remove and Place the master disconnect switch in the ON
discard O-ring face seals from flange heads of position.
hoses.

Copyright
8001-16
STEP 80 STEP 81
Start the engine and run the engine at low idle for two Stop the engine and check for hydraulic oil leakage
minutes. at the hydraulic pump.
NOTE: If any unusual vibration is heard coming from
the pump, stop the machine immediately and check STEP 82
for obstructions in the pump suction line. Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.

Copyright
8001-17
LIFT CYLINDERS
Removal STEP 87
STEP 83
parking brake.
BD01D709
STEP 84 Loosen and remove the bolt, washer and spacer that
Relieve the pressure in the ride control accumulator hold the pivot pin for the yoke.
with the manual bleeder valve located at the rear of
the front chassis. STEP 88
STEP 85
Loosen the filler cap on the hydraulic reservoir to
release any pressure.
STEP 86
BD01D711
Use a proper lifting device and secure a strap around

the lift cylinder.
STEP 89
BD01D708
Tag and disconnect the hoses on each side of the lift

cylinder. Install plugs in the hoses and caps on the
fittings.
BD01D712
Remove the pivot pin from the yoke end of the lift
cylinder.

Copyright
8001-18
STEP 90 Installation
STEP 93
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.
STEP 94
BD01D710
Loosen and remove the bolt, washer and spacer that

hold the pivot pin at the closed end of the lift cylinder.
STEP 91
BD01D714
Use a proper lifting device and position the lift

cylinder on the machine.
STEP 95
BD01D713
Remove the pivot pin from the closed end of the lift
cylinder.
STEP 92
Remove the lift cylinder from the machine
BD01D713
Align the closed end of the lift cylinder with the front
frame and install the pivot pin.

Copyright
8001-19
STEP 96 STEP 99
BD01D710 BD01D712
Align the pivot pin with the front frame and install the Install the pivot pin for the yoke. Stop the engine.
spacer, washer and bolt. Tighten the bolt.
STEP 100
STEP 97
BD01D709
BD01D708 Align the pivot pin with the yoke and install the
Remove the caps and plugs and connect the hoses spacer, washer and bolt. Tighten the bolt.
to the lift cylinder.
STEP 101
STEP 98 SLOWLY extend and retract the piston rod three
If the yoke of the lift cylinder is not aligned with the times to remove any air from the lift cylinders.
loader frame, have another person start and run the
engine at low idle and use the loader control lever to STEP 102
SLOWLY move the yoke into alignment with the Lubricate the pivot pins with molydisulfide grease.
loader frame.
STEP 103
Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the

Copyright
8001-20
BUCKET CYLINDER - Z-BAR LOADER
Removal STEP 108
STEP 104
parking brake.
STEP 105
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.
STEP 106
BD01D695
Loosen and remove the two bolts that fasten the

mounting bracket to the machine. Remove the
mounting bracket.
STEP 109
BD01D694
Disconnect the proximity switch connector from the

wiring harness connector.
STEP 107
BD01D697

mounting bracket for the proximity switch to the
bucket cylinder. Remove the mounting bracket and
switch.
BD01D696

target bar to the mounting bracket. Remove the
target bar.

Copyright
8001-21
STEP 110 STEP 113
BD01D699 BD01D701
Disconnect the hoses from each side of the bucket Remove the pivot pin from the rod end of the bucket
cylinder. Install plugs in the hoses and caps on the cylinder.
fittings.
STEP 114
STEP 111
BD01D704
BD01D700 Remove the pivot pin from the head end of the
Use acceptable equipment to hold the bucket bucket cylinder.
cylinder.
NOTE: It is not necessary to remove the grease line
from the pivot pin unless the pivot pin is to be
STEP 112 replaced.
STEP 115
BD01D698
Loosen and remove the bolt, washer and spacer that

fasten the pivot pin from both ends of the bucket
BD01D706
cylinder.
Raise the bucket cylinder and remove the cylinder
from the machine.

Copyright
8001-22
Installation STEP 120
STEP 116
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.
STEP 117
BD01D699
Connect the hoses to each side of the bucket

cylinder.
STEP 121
If the rod end of the bucket cylinder is not aligned
with the bellcrank, have another person start the
BD01D706
engine and run the engine at low idle and use the
Use acceptable lifting equipment to lower the bucket bucket control lever to SLOWLY move the piston rod
cylinder into position. eye into alignment with the bellcrank.
STEP 118 STEP 122

Install the pivot pin and stop the engine.
STEP 123
BD01D704
Install the pivot pin to the head end of the bucket

cylinder.
BD01D698
STEP 119 Install the spacer, washer and bolt that fasten the
Install the spacer, washer and bolt that fasten the pivot pin to the bellcrank. Tighten the bolt.
pivot pin to the front frame. Tighten the bolt.
NOTE: If a new pivot pin is being installed, connect
the grease line to the pivot pin.

Copyright
8001-23
STEP 124 STEP 127
BD01D697 BD01D694
Install the two bolts that fasten the mounting bracket Connect the proximity switch connector to the wiring
for the switch to the bucket cylinder. harness connector.
STEP 125 STEP 128

See Section 9006 for the adjustment procedure for
adjusting the proximity switch.
STEP 129
Start and run the engine at low idle.
STEP 130
SLOWLY extend and retract the piston rod three
times to remove any air from the bucket cylinder.
STEP 131
Lubricate the pivot pins with molydisulfide grease.
BD01D695
Install the two bolts for the mounting bracket for the STEP 132
target bar.
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
STEP 126 hydraulic reservoir.
BD01D696
Install the two bolts that fasten the target bar to the
mounting bracket.

Copyright
8001-24
OIL COOLER
Removal STEP 138
STEP 133
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 134
position.
STEP 135
Raise the engine hood and remove the shield on the
right side of the machine between the tire and the oil BD03A154
cooler. Disconnect the top hose and install a plug in the hose
and a cap on the fitting.
STEP 136
STEP 139
BD03A120
Have assistant hold side panel in raised position,

BD03A179
remove two mounting screws, remove side panel.
Loosen and remove the bolt and washer that fasten
the oil cooler to the cooling frame.
STEP 137
STEP 140
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.
BD06H195
Disconnect the hose from the bottom of the oil
cooler. Install a plug in the hose and a cap on the
fitting. Remove the two mounting nuts, remove the oil
cooler from the machine.

Copyright
8001-25
STEP 141
BD03A120
Have assistant hold side panel in raised position,

install and tighten two mounting screws.
BD06H195
Place the oil cooler in position in the cooling frame.

Connect the lower hose to the oil cooler, install and STEP 145
tighten the two mounting nuts. Turn off the vacuum pump and disconnect from the
STEP 142
STEP 146
position.
STEP 147
Start the engine and run the engine at low idle for two
minutes. Stop the engine and check for hydraulic oil
leakage at the ports on the oil cooler.
STEP 148
Install the shield between the right rear tire and the
oil cooler and tighten the two bolts holding the shield.
BD03A179
Install the bolt and washer that fasten the oil cooler to STEP 149
the cooling frame Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
STEP 143
BD03A154
Connect the hose to the top of the oil cooler.

Copyright
8001-26
RIDE CONTROL ACCUMULATOR
Removal STEP 153
STEP 150
parking brake.
circuit, turn ignition switch OFF. BD06H196
Disconnect the hose from the elbow at the bottom of
STEP 151 the ride control accumulator. Install a plug in the
hose and a cap on the fitting.
STEP 154
BD06H198

the ride control valve. Remove the plug and turn the BD06H197
valve two turns counter-clockwise. Loosen and remove the nuts and washers from the
U-bolt. Remove the U-bolt.
STEP 152
STEP 155
accumulator bracket to the front frame. Remove the
ride control accumulator from the machine.
pump.

Copyright
8001-27
STEP 156
Place the ride control accumulator in position on the
front frame.
STEP 157
Install the two bolts that fasten the accumulator
bracket to the front frame. Tighten the bolts.
STEP 158
BD06H196
Remove the caps and plugs and install the hose on

the elbow at the bottom of the ride control
accumulator.
STEP 160
Turn off and disconnect the vacuum pump from the
STEP 161
BD06H197
Tighten the accumulator manual bleeder valve
Install the U-bolt, washers and nuts. Tighten the nuts. located on the top of the ride control valve to a torque
of 3.5 Nm (31 lb-in). Install the plug and torque to
7 Nm (62 lb-in).
STEP 162
Refer to Section 8002 Testing the Ride Control for
the proper charging of the accumulator to check for
leaks.
STEP 163

Copyright
8001-28
RIDE CONTROL VALVE
Removal STEP 166

STEP 164 release the air pressure in the reservoir. Connect a
Park the machine on a level surface and lower the vacuum pump to the hydraulic reservoir, turn on the
bucket to the floor. Stop the engine and apply the pump.
parking brake.
STEP 167
position.
loader control valve back and forth several times to STEP 168
release any hydraulic pressure in the pilot control Disconnect the electrical connector on top of the ride
circuit, turn ignition switch OFF. control valve.
STEP 165 STEP 169

Tag and disconnect the hoses from the ride control
valve. Install a plug in the hoses and caps on fittings.
STEP 170
Loosen and remove the two bolts and washers that
fasten the ride control valve to the frame.
STEP 171
Remove the ride control valve from the machine.
STEP 172
BD06H198 Remove and discard all O-rings.
the ride control valve. Remove the plug and turn the
valve two turns counter-clockwise.

Copyright
8001-29

Connect the electrical connector to the ride control
STEP 173 valve.
Install the ride control valve in position on the front
frame. STEP 179
STEP 174 hydraulic reservoir.
Install the washers and bolts through the frame and
into the ride control valve. Tighten the bolts. STEP 180
STEP 175 position.
STEP 181
Start and run the engine at low idle for two minutes.
STEP 182
Stop the engine and check for hydraulic oil leakage
at the ride control valve.
STEP 183
BD06H198 hydraulic reservoir.
Tighten the accumulator manual bleeder valve
located on the top of the ride control valve to a torque STEP 184
of 3.5 Nm (31 lb-in). Install the plug and torque to Refer to Section 8002 and perform the Ride Control
7 Nm (62 lb-in). Test Procedure.
STEP 176
Lubricate and install new O-rings.
STEP 177
Connect the hoses to the ride control valve.

Copyright
8001-30
FAN REVERSING VALVE
Removal STEP 188
STEP 185
parking brake.
the brake repeatedly to be sure the brake 2
1
BD03A174
STEP 186 Tag and disconnect the fan forward hose (1) from the
Loosen the filler cap on the hydraulic reservoir to fan reversing valve. Install a plug in the hose and a
release the air pressure in the reservoir. Connect a cap on the fitting. Tag and disconnect the fan reverse
vacuum pump to the hydraulic reservoir, turn on the hose (2) from the fan reversing valve. Install a plug in
pump. the hose and a cap on the fitting.
STEP 187 STEP 189
3
4
BD03A173
BD03A174
Tag and disconnect the fan valve return hose (3)
Disconnect the electrical connector for the fan from the fan reversing valve. Install a plug in the hose
reversing valve. and a cap on the fitting. Tag and disconnect the fan
valve supply hose (4) from the fan reversing valve.
Install a plug in the hose and a cap on the fitting.
STEP 190
Loosen and remove the nuts, washers and bolts.
STEP 191
Remove the fan reversing valve from the machine.
STEP 192
Remove and discard all O-rings from the fittings.

Copyright
8001-31
STEP 193
Place the fan reversing valve into position on the
machine.
STEP 194
Lubricate and install new O-rings in the fittings.
STEP 195
Install the bolts, washers and nuts. Tighten the nuts.
STEP 196
BD03A174
Connect the electrical connector for the fan reversing

valve.
STEP 199
STEP 200
3 Check the level of the hydraulic oil in the reservoir.
4
STEP 201
BD03A173
Connect the fan valve supply hose (4) to the fitting on Start the engine and run the engine at low idle for two
the fan reversing valve. Connect the fan valve return minutes.
hose (3) to the elbow on the fan reversing valve.
STEP 202
STEP 197 Stop the engine and check for hydraulic oil leakage
at the fan reversing valve.
STEP 203
reservoir.
BD03A174
Connect the fan reverse hose (2) to the fitting on the

fan reversing valve. Connect the fan forward hose (1)
to the fitting on the fan reversing valve.

Copyright
8001-32
THERMAL VALVE
Removal Installation
STEP 204 STEP 208
Park the machine on a level surface and lower the Place the thermal valve into position on the machine.
parking brake. STEP 209
IMPORTANT: With the engine NOT running, pump Lubricate and install new O-rings in the fittings.
accumulators have no hydraulic pressure, put the STEP 210
ignition switch in the ON position then move the Install the bolts, washers and nuts. Tighten the nuts.
release any hydraulic pressure in the pilot control STEP 211
Connect the hoses to the thermal valve, remove and
discard tags.
STEP 205
Loosen the filler cap on the hydraulic reservoir to STEP 212
pump.
STEP 213
STEP 206
Check the level of the hydraulic oil in the reservoir.
STEP 214
Start the engine and run the engine at low idle for two
minutes.
STEP 215
Stop the engine and check for hydraulic oil leakage
at the thermal valve.
STEP 216
BD06F211
Tag and disconnect the hoses from the thermal and add as required. Tighten the filler cap on the
valve. Install a plug in the hose and a cap on the reservoir.
fitting.
STEP 207
Remove the mounting bolts from the thermal valve,
remove the valve from the machine.

Copyright
8002
Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,

AND PRESSURE CHECKS

Copyright
8002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problems in All Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in All Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TESTING AND ADJUSTING THE HIGH PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the High Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTING AND ADJUSTING THE LOW PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjusting the Low Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjusting the Loader Pump Cutoff Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HIGH PRESSURE PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Copyright
8002-3
SPECIFICATIONS
Manufacturer ....................................................................................................................................... Bosch-Rexroth
High pressure pump (closest to transmission) ....................................................120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 2500 psi at 2000rpm)
Low pressure pump (furthest from transmission) ................................................120 L/min at 172 bar, at 2000 r/min
(31.6 gpm at 2500 psi at 2000rpm)
Main relief valve pressure settings .........................................................................248 to 255 bar (3600 to 3700 psi)
Circuit relief valve pressure setting
Auxiliary A and B port.................................................................................................................290 bar (4200 psi)
Bucket A port..............................................................................................................................290 bar (4200 psi)
Bucket B port..............................................................................................................................290 bar (4200 psi)
Steering relief valve pressure setting ............................................................................................ See Section 5002
Accumulator pressure .................................................................................................................... See Section 7002
NOTE: Both pump sections provide flow for both the steering and loader functions.

Copyright
8002-4
SPECIAL TOOLS
633L95 B877168V
CAS-1904 PRESSURE FITTING KIT CAS-1808 FLOWMETER FITTING KIT
632L95 B877895M
CAS-1906 PRESSURE FITTING KIT CAS-10090 HAND PUMP
B785789M B877558M
CAS-10280 FLOWMETER CAS-1804 PRESSURE FITTING KIT

Copyright
8002-5
TROUBLESHOOTING PROCEDURE
Visually check the machine for oil leakage and

damaged or missing parts. Repair or replace
any damaged or missing parts.
Check the oil level in the hydraulic reservoir. Is Fill the hydraulic reservoir with the hydraulic oil
No specified in Section 1002.
the oil level correct?.
Yes
Heat the oil in the hydraulic system to

operating temperature. Operate the
machine to find which circuits have
problems.
Problems in All Circuits

Replace the return line hydraulic filter.
See Section 2002. Do the stall test to see if
the engine is good.
See Section 8003 and check for contaminated See Page 18. Do the flow meter test of the
No hydraulic pump.
oil. Is the oil contaminated?
Yes
See Section 8003 and clean or replace the

oil.
Problem in All Loader Circuits

See Page 11 and check the pressure setting
Adjust the limit pressure. See page 11 in this
of the limit pressure in the loader control No section.
valve. Is the pressure setting correct?
Problem in the Braking Circuit

See Section 7002 and check the braking
circuit.

Copyright
8002-6
Problem in a Single Loader Circuit

Start and run the engine at full throttle. The loader control valve is damaged. See
Operate the control for the bad circuit. Does No Section 8005 and repair the loader control
the cylinder move in both directions? valve
Yes
Check the cylinder piston packing. Is the See Section 8006 and repair the cylinder.
No
packing good?
Yes
See Page 20. Check and adjust the circuit See Section 8005. Disassemble the loader
relief valves. Then check the operation of control valve and check for worn or
No
the circuit again. Does the circuit work damaged parts.
correctly?
Yes
The problem is repaired.
Problem in the Steering Circuit

See Section 5002 and check the steering
No Repair the component as necessary.
circuit. Is the steering circuit good?
Yes
See Page 13. Do the Steering Pump Limit

Pressure Test and Adjustment
Problem in the Ride Control

Lift arms rapidly and continuously sink See the Ride Control Test Procedure page
towards the ground. No 21 in this section.
Yes
Check the manual bleed valve for the ride

control accumulator to be sure that it is
closed.

Copyright
8002-7
TESTING AND ADJUSTING THE HIGH PRESSURE

PUMP DIFFERENTIAL PRESSURE
Pressure Check STEP 3
STEP 1
BD06G180
BD00M041
1. ARTICULATION LOCK 2
Install articulation lock (1).
STEP 2
Make sure that the temperature of the hydraulic oil is
at least 54C to 57C (129F to 135F). The following
is the procedure for heating the hydraulic oil.
BD06F148
A. Start the engine and run at full throttle. 1. TEST PORT (LOAD SENSE)
2. TEST PORT (PUMP PRESSURE)
B. Lower the loader bucket to the ground and
hold the lift control lever in the FLOAT
position. Connect two 69 bar (1000 psi) test gauges, one to
the test port (2) located on the priority valve, and one
C. Roll the bucket back against the stops and on the pump load-sense pressure tap (1 closest to
hold. transmission).
D. View the oil temperature by pressing the down IMPORTANT: Do not steer or operate loader
arrow on the key pad to display hydraulic oil controls while the gauges are connected, gauges
temperature. could be damaged.
After heating oil to operating temperature, lower
bucket to the ground, turn off the engine, and relieve STEP 4
all pressure in the hydraulic system. Start the engine and run at low idle.
STEP 5
Make sure all of the controls are in the neutral
position and record the readings on the test gauges
(1) and (2).
STEP 6
Subtract the reading of the test port (1) from the
reading of the test port (2).

Copyright
8002-8
STEP 7 Adjusting the High Pressure Pump
The difference between the two readings should be Differential Pressure
24 to 27 bar (350 to 390 psi).
STEP 9
STEP 8
The load-sense adjusting screw is directly below the
If this reading is more or less than specified, it will be load-sense pressure tap. Turn the screw clockwise to
necessary to adjust the pump load-sense pressure. increase the load-sense pressure. Turning the screw
counterclockwise will decrease the load-sense
pressure.
NOTE: One turn of the adjustment screw will change
the pressure approximately 16 bar (230 psi).

Copyright
8002-9
TESTING AND ADJUSTING THE LOW PRESSURE

PUMP DIFFERENTIAL PRESSURE
STEP 1
BD06G180
1
2
BD00M041
1. ARTICULATION LOCK
STEP 2
at least 54C to 57C (129F to 135F). The following
BD06F148
A. Start the engine and run at full throttle. 1. TEST PORT (LOAD SENSE)
2. TEST PORT (PUMP PRESSURE)
position. Connect two 69 bar (1000 psi) test gauges, one to
the test port (2) located on the priority valve, and one
C. Roll the bucket back against the stops and on the pump load-sense pressure tap (1 furthest from
hold. the transmission).
To measure the oil temperature with the IMPORTANT: Do not steer of operate loader
instrument cluster: controls while the gauges are connected, gauges
A. Press the up or down arrow key. could be damaged.
B. Stop at the info screen with the temperatures STEP 4

that need to be monitored are on.
Start the engine and run at low idle.
bucket to the ground, turn off the engine, and relieve STEP 5
all pressure in the hydraulic system.
Make sure all of the controls are in the neutral
position and record the readings on the test gauges
(1) and (2).
STEP 6
Subtract the reading of the test port (1) from the
reading of the test port (2).

Copyright
8002-10
STEP 7 Adjusting the Low Pressure Pump
The difference between the two readings should be Differential Pressure
25 to 28 bar (360 to 400 psi).
STEP 9
STEP 8
The differential adjusting screw is directly below the
If this reading is more or less than specified, it will be load-sense pressure tap. Turn the screw clockwise to
necessary to adjust the pump differential pressure. increase the load-sense pressure. Turning the screw
counterclockwise will decrease the differential
pressure.

Copyright
8002-11
TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE

STEP 1 at least 54C to 57C (129F to 135F). The following
A. Start the engine and run at full throttle.
position.
C. Roll the bucket back against the stops and
hold.
To measure the oil temperature with the
instrument cluster:
1
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures
BD00M041
bucket to the ground, turn off the engine, and relieve
STEP 2
STEP 4
Run the engine at full throttle.
STEP 5
1 Roll the loader bucket back against the stops.
STEP 6
Record the reading on the test gauge.
STEP 7
Reading should be 248 to 255 bar (3600 to 3700 psi).
BD06F148
1. TEST PORT (LOAD LIMIT) STEP 8

If this reading is more or less than specified, it will be
Connect a 345 bar (5000 psi) test gauge to the test necessary to adjust the pump limit pressure.
port (1), located on the priority valve.

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8002-12
Adjusting the Loader Limit STEP 9

Pressure The limit adjusting screw is located on the left side of
the loader valve. Turn the screw clockwise to
increase the limit pressure. Turning the screw
counterclockwise will decrease the limit pressure.
BD06H193

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8002-13
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE

position.
hold.
instrument cluster:
1
BD00M041
STEP 2
STEP 4
Start the engine and run at full throttle.
STEP 5
1 Steer hard in either direction over relief pressure.
STEP 6
STEP 7
BD06F148
1. TEST PORT (LOAD LIMIT) STEP 8

Connect a 345 bar (5000 psi) test gauge to the test necessary to adjust the steering limit pressure.
port (1), located on the priority valve.

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8002-14
Adjusting the Steering Limit STEP 9

Pressure The steering priority valve is located on the hydraulic
pump, the adjusting valve is located on the
transmission side of the priority valve. Turning the
screw clockwise to increase the limit pressure.
Turning the screw counterclockwise will decrease the
limit pressure.
BD06F147
1. STEERING LIMIT VALVE

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8002-15
TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE

position.
hold.
instrument cluster:
1
BD00M041
STEP 2
STEP 4
1 Start the engine and run at full throttle.
STEP 5
Roll the loader bucket back against the stops.
STEP 6
STEP 7
BD06F148
1. TEST PORT (PUMP PRESSURE) STEP 8

Connect two 345 bar (5000 psi) test gauge to the test necessary to adjust the pump cutoff pressure.
port (1) located on the large hydraulic tube on the
bottom of the pump.

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8002-16
Adjusting the Loader Pump Cutoff

Pressure
STEP 9
BD06G179
The unloading adjuster is the longer of the two

adjusters on the loader pump. Turn the screw
clockwise to increase the cutoff pressure. Turning
the screw counterclockwise will decrease the cutoff
pressure.
NOTE: The adjusting screw is located just above the
steering priority valve on the pump furthest from the
transmission.

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8002-17
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE

NOTE: This pressure is factory preset and is not STEP 2
adjustable. Raise lift arms to the top and turn off the engine. Turn
the ignition switch to the RUN position and
Pressure Check disengage the controller lock-out switch.
STEP 1 STEP 3
Make sure that the temperature of the hydraulic oil is Wait for the buzzer to stop then repeatedly put the
at least 54C to 57C (129F to 135F). The following loader control lever into FLOAT position and back
is the procedure for heating the hydraulic oil. to neutral.
STEP 4
B. Lower the loader bucket to the ground and The system should allow a minimum of 10 actuations
hold the lift control lever in the FLOAT into float and still cause the lift arms to come down.
position.
NOTE: If 10 full actuations cannot be made, an
C. Roll the bucket back against the stops and internal hydraulic leak exists.
hold.
instrument cluster:

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8002-18
HIGH PRESSURE PUMP FLOW TEST

NOTE: The pump differential pressure must be set STEP 6
before attempting any other tests. Refer to page 7 of Using the temperature gauge on the flow meter,
this section. continue to run the engine at high idle until the
temperature of the hydraulic oil is at least 52C to
STEP 1 60C (125F to 140F).
Connect the flow meter (3) by disconnecting the inlet
hose (6) to the valve supply tube (13), installing a cap STEP 7
(12) on the fitting at the valve supply tube (13). Refer Run the engine at low idle, fully open the flow meter
to illustration on page 19. valve.
STEP 2 STEP 8
Disconnect the load sense hose (7) and install a cap Open the needle valve (8) and operate the engine at
(12) the fitting at the loader valve (15). 2000 rpm. At 0 bar (0 psi) the flow should be 250 to
NOTE: This is the line that returns to the pump 255 L/min (66 to 67.4 gpm).
compensator valve.
STEP 9
STEP 3 Close the flow meter valve slowly and read the flow
Connect a T fitting (10) into the loader control valve at 34.5 bar (500 psi) the flow should be 249 to 255
inlet hose (6) and to the flow meter inlet hose (11). L/min (65.8 to 66.8 gpm).
STEP 4 STEP 10
Use a union (9) and connect an in line needle valve Close the flow meter valve slowly and read the flow
(8) to the open port in the T fitting (10), connect the at 2000 psi @ 2000 rpm. The flow should read 244.5
load sense hose (7) to the needle valve (8). to 247.5 L/min (64.6 to 65.4 gpm).
STEP 5 STEP 11
Make sure that the flow meter valve and the installed Continue to close the flow meter valve slowly, at
needle valve are in the open position. Start and run approximately 2900 psi the flow should drop
the engine at high idle, slowly close the flow meter significantly, this will be the low pressure pump
valve until a pressure reading of 103 bar (1500 psi) is destroking.
obtained.
STEP 12
Continue slowly closing the flow meter valve until
3500 psi is reached. The flow should read between
120 to 122 L/min (31.6 and 32.1 gpm).
STEP 13
If any of the pump flow readings are not within
specifications, the pump may be out of calibration
and Technical Support Services should be
contacted.

Copyright
8002-19
2 4
3
5
6
11
12
13
7
10
9
12
8
14
15
BS06G117
1. HYDRAULIC RETURN MANIFOLD 6. HOSE M42 ORB 11. FLOW METER INLET HOSE
2. FLOW METER RETURN HOSE 7. LOAD SENSE HOSE M14 ORB 12. CAP
3. FLOW METER 8. NEEDLE VALVE 13. VALVE TUBE SUPPLY
4. PUMPS 9. UNION 14. ELBOW M14 ORB
5. PRIORITY VALVE 10. T FITTING 15. LOADER VALVE
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

Copyright
8002-20
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES

Remove the safety strut and lower the bucket to the
STEP 1 floor. Shut off the engine. Find an easy place to
Circuit relief valves are located as shown below. disconnect the line for the circuit to be tested.
4 STEP 5
3 5
1 Connect the hand pump to the disconnected line that
1 goes to the loader control valve.
2
STEP 6
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21C (70F).
STEP 7
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
6 be sure of the reading.
STEP 8
Compare the reading to the specifications on Page 3.
STEP 9
1 If the pressure is not correct, adjust the circuit relief
1
valve.
3 5
4 Adjustment
BS03B022
1. CIRCUIT RELIEF VALVES STEP 1

2. PUMP LIMIT PRESSURE ADJUSTMENT Loosen the lock nut. Turn the adjustment screw
3. BUCKET SPOOL
clockwise to increase the pressure or
4. LIFT SPOOL
counterclockwise to decrease the pressure.
5. AUXILIARY SPOOL
6. LOADER CONTROL VALVE NOTE: One turn of the adjusting screw will change
STEP 2
Raise the lift arms and install the safety link on the lift STEP 2
arm cylinder. Check the pressure again. Repeat the adjustment as
necessary.
STEP 3
Loosen and remove the bolts and washers that
fasten the access cover plate for the loader control
valve. Remove the cover plate.

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8002-21
TESTING THE RIDE CONTROL

STEP 1 STEP 6
Move the machine to a clear level surface with Dump the bucket until it hits the dump stops. Hold the
clearance for full lift arm and bucket movement. bucket in the dump position for 5 to 10 seconds.
NOTE: This will charge the ride control accumulator.
STEP 2
Install the articulation lock, start the machine, STEP 7
activate the parking brake.
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
STEP 3 their stops, place the pilot control lever in the neutral
With the pilot controller in neutral, set the ride control position.
rocker switch on the right side console to the Always
On position and observe the switch lamp, the lamp STEP 8
should illuminate.
Set the ride control rocker switch to the Always On
position. The lift arms should rise 15 to 30 cm (6 to
STEP 4 12 inches) with an empty bucket.
Set the ride control rocker switch to the Off position
and observe the switch lamp, the lamp should go out. NOTE: Test results will be for a machine with a
empty factory bucket and no attachments.
NOTE: This indicates that the switch is operating
correctly and has power, if the switch does not STEP 9
illuminate see section 4002 and troubleshoot the
If there is little or no lift arm raise, the test may have
electrical system for the ride control.
been done too slowly. The elapsed time between
step 6 and step 8 should not exceed six seconds.
STEP 5
Raise the lift arms to the top of their travel and dump NOTE: If test was done to slowly repeat in the
the bucket. allotted time.
STEP 10
If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
accumulator, see section 8013.

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8002-22
HYDRAULIC COMPONENT LOCATIONS
5
6 8
7
9
4 10
2 8
3
11
15 12
14 13
16
19
18
17
1
BC00N140
1. REAR BRAKE CYLINDERS 11. FRONT BRAKE CYLINDERS
2. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC 12. RIDE CONTROL ACCUMULATOR BLEEDER VALVE AND
COUPLER RIDE CONTROL VALVE (OPTIONAL)
3. BRAKE ACCUMULATORS 13. PARKING BRAKE CYLINDER
4. FRONT AND REAR AXLE BRAKE PRESSURE 14. STEERING PRESSURE DIAGNOSTIC COUPLER
DIAGNOSTIC COUPLERS 15. STEERING PRIORITY VALVE
5. BRAKE LIGHT PRESSURE SWITCH 16. STEERING CYLINDERS
6. BRAKE WARNING PRESSURE SWITCH 17. AUXILIARY STEERING PUMP AND MOTOR
7. BRAKE AND ACCUMULATOR CHARGING VALVE 18. AUXILIARY STEERING PRIORITY VALVE
8. LIFT CYLINDERS
19. AUXILIARY STEERING PRESSURE SWITCH
9. BUCKET CYLINDER (TILT CYLINDER)
10. RIDE CONTROL ACCUMULATOR
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.

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8002-23
23
24
21 25
26
22
20
30
29 27
28
31
32
33
34
BC00N140
20. FAN DRIVE MOTOR 28. PUMP PRESSURE DIAGNOSTIC COUPLER

21. HYDRAULIC RESERVOIR BREATHER 29. LOAD SENSING DIAGNOSTIC COUPLER
22. HYDRAULIC RESERVOIR 30. IMPLEMENT HYDRAULIC PUMP
23. PILOT PRESSURE DIAGNOSTIC COUPLER 31. HYDRAULIC FILTER
24. PILOT CONTROL VALVE 32. HYDRAULIC COOLER
25. PILOT PRESSURE ACCUMULATOR 33. BRAKE HYDRAULIC PUMP
26. LOADER CONTROL VALVE 34. FAN VALVE
27. PARKING BRAKE ACCUMULATOR
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.

Copyright
8002-24
NOTES

Copyright
Section
8003
8003
CLEANING THE HYDRAULIC SYSTEM

Copyright
8003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
87551879A Revised 1-07 Printed in E.C.

Copyright
8003-3
SPECIAL TOOLS
806128
CAS10508, fitting kit.
806127
CAS101162A, filter unit, portable.
TR98H032
CAS10192, vacuum pump.

Copyright
8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major 1. Cylinder rod seals leak.
cause of the malfunction of hydraulic components.
2. Control valve spools do not return to neutral.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in 3. Movement of control valve spools is difficult.
several ways.
4. Hydraulic oil becomes too hot.
1. When you drain the oil or disconnect any line.
5. Pump gears, housing, and other parts wear
2. When you disassemble a component. rapidly.
3. From normal wear of the hydraulic components. 6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals. 7. Quick failure of components that have been
repaired.
5. From a damaged component in the hydraulic
system. 8. Cycle times are slow; machine does not have
enough power.
All hydraulic systems operate with some
contamination. The design of the components in this If your machine has any of these problems, check
hydraulic system permits efficient operation with a the hydraulic oil for contamination. See types of
small amount of contamination. An increase in this contamination below. If you find contamination, use
amount of contamination can cause problems in the the Portable Filter to clean the hydraulic system.
hydraulic system. The following list includes some of
these problems.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic 3. Visible contamination is foreign material that can
and visible. be found by sight, touch, or odor. Visible
contamination can cause a sudden failure of
1. Microscopic contamination occurs when very fine
components. Examples of visible contamination:
particles of foreign material are in suspension in
the hydraulic oil. A. Particles of metal or dirt in the oil.
2. These particles are too small to see or feel. B. Air in the oil
Microscopic contamination can be found by
C. The oil is dark and thick.
identification of the following problems or by
testing in a laboratory. Examples of the D. The oil has an odor of burned oil.
problems:
E. Water in the oil. See page 7.
A. Cylinder rod seal leak.
B. Control valve spools do not return to
NEUTRAL.
C. The hydraulic system has a high operating
temperature.

Copyright
8003-5
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the 8. Using the fitting kit shown on page 3, install the
following steps: valve in the hole for the drain plug. Make sure
that the valve is closed.
A. Remove all the hydraulic oil from the inlet and
outlet hoses for the portable filter. 9. Stop the vacuum pump.
B. Remove the filter element from the portable 10. Connect the inlet hose for the portable filter to
filter. the valve that is installed in the hole for the drain
plug.
C. Remove all hydraulic oil from the portable
filter. 11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler
D. Clean the inside of the housing for the filter
cap.
element.
12. Install the outlet hose for the portable filter in the
2. You must know whether the contamination is
hydraulic reservoir filler neck.
microscopic or visible. See types of
contamination on page 4. 13. Open the valve that is installed in the hole for the
drain plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON
A. Check the maintenance schedule for the
position. Start and run the engine at 1500 rpm
machine to learn if the hydraulic oil must be
(r/min).
changed. If needed, change the hydraulic oil.
See Section 1002 for specifications. Change 15. Run the portable filter for 10 minutes.
the hydraulic filter.
16. Continue to run the portable filter. Increase the
B. Do steps 6 through 35. engine speed to full throttle. Heat the oil to
operating temperature by doing the following
4. If the contamination is visible:
steps:
A. Change the hydraulic oil and hydraulic filter. A. Hold the blade control lever in the TILT
See Section 1002 for specifications. position for five seconds.
B. Do steps 5 through 35. B. Return the blade control lever in the
5. Check the amount of contamination in the NEUTRAL position for five seconds.
hydraulic system by doing the following steps: C. Repeat steps A and B until the oil in the
hydraulic system is at operating temperature.
A. Disassemble one cylinder in two different
circuits. Check for damage to seals, scoring of 17. Continue to run the engine at full throttle.
the cylinder wall, etc. Repair the cylinders as Continue to run the portable filter.
necessary.
18. Operate each hydraulic circuit to completely
B. If, in your judgment, the damage to the extend and retract the cylinders. Continue to
cylinders was caused by sever contamination operate each hydraulic circuit two times, one
and is not the result of normal wear, it is after the other for 45 minutes.
necessary to remove, clean and repair valves,
19. Decrease the engine speed to low idle.
pump, lines, cylinders, hydraulic reservoir, etc.
in the hydraulic system. 20. Continue to run the portable filter for 10 minutes.
6. Remove the breather from the reservoir and 21. Stop the portable filter.
connect the vacuum pump to the opening. Start
22. Stop the engine.
the vacuum pump.
23. Remove the hose from the hydraulic reservoir.
7. Loosen and remove the drain plug from the
reservoir.

Copyright
8003-6
24. Close the valve that is installed in the hole for the 30. Stop the vacuum pump. Disconnect the vacuum
drain plug. pump from the opening in the reservoir and
install the breather.
25. Disconnect the inlet hose for the portable filter
from the valve. Remove the outlet hose from the 31. Remove the hydraulic filter elements from the
reservoir filler neck and replace filler cap. machine.
26. Connect a vacuum pump to the breather hose of 32. Install new hydraulic filter elements on the
the hydraulic reservoir. machine.
27. Start the vacuum pump. 33. Start the engine. Check for oil leakage around
the new hydraulic filters.
28. Remove the valve from the hole for the drain
plug. 34. Stop the engine.
29. Install the drain plug. 35. Check the oil level in the hydraulic reservoir. Add
oil as required. See Section 1002 for
specifications.

Copyright
8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min). 13. Slowly move each control lever in both directions
until oil begins to flow from the open line. Hold
2. Completely retract the cylinders of all
the control lever in place until clean oil flows from
attachments on the machine. Angle the blade to
the open line.
the right, the right cylinder will be fully retracted
and the left will be fully extended. Stop the 14. Stop the engine.
engine.
15. Connect the system line to the CLOSED end of
each cylinder.
WARNING: If retracting the cylinder rods
causes the attachments to be raised, block 16. Connect a suitable drain line to the OPEN end of
the attachments in place before proceeding each cylinder and place the other end in an
to the next step! acceptable container for contaminated oil.
39-4
17. Start the engine and run the engine at low idle.
NOTE: Any attachment or part of an attachment that 18. Slowly and completely extend all cylinders. As
is raised must be supported with acceptable the piston rod comes in/out of the cylinder, oil will
equipment to prevent the attachment from falling. be pushed out of the OPEN end of the cylinders.
3. Move each control lever in both directions to NOTE: Any attachment or part of an attachment that
release pressure in the hydraulic circuits. is raised must be supported with acceptable
4. Loosen and remove the filler cap from the equipment to prevent the attachment from falling.
reservoir. 19. Support any attachments that will be in the
5. Drain the hydraulic oil from the reservoir. RAISED position.
A. See Section 1002 for capacity specifications. 20. Stop the engine.
B. Have available acceptable equipment to drain 21. Disconnect the drain lines and connect the
the hydraulic oil. system lines to the cylinders.
C. Remove the drain plug from the bottom of the 22. Check the oil level in the hydraulic reservoir. Add
reservoir. oil as required. See Section 1002 for
specifications.
6. Remove the hydraulic filter elements from the
machine. 23. Install the filler cap on the reservoir.
7. Install new hydraulic filter elements on the 24. Remove the hydraulic filter elements from the
machine. machine.
8. Install the drain plug in the bottom of the 25. Install new hydraulic filter elements on the
reservoir. machine.
9. Fill the hydraulic reservoir with hydraulic fluid. 26. Start and run the engine at 1500 rpm (r/min),
See Section 1002 for specifications. operate each hydraulic circuit to completely
extend and retract the cylinders.
10. Disconnect the line from the OPEN end and
CLOSED end of each cylinder. 27. Stop the engine and check for leaks. Check the
oil level in the hydraulic reservoir. Add oil as
11. Be sure all control levers are in the NEUTRAL required. See Section 1002 for specifications.
position.
12. Start and run the engine at low idle.
IMPORTANT: Check the oil level in the hydraulic
reservoir frequently while doing step 13. Have
another person hold a container under the hydraulic
lines while you do step 13.

Copyright
8003-8
NOTES

Copyright
Section
8004
8004
HYDRAULIC PUMP
Copyright 2007 CNH Italia S.p.A..

Copyright
8004-2
TABLE OF CONTENTS
PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Copyright
8004-3
PUMP SPECIFICATIONS
Manufacturer .................................................................................................................................................. Rexroth
High pressure pump (steering pump next to transmission) .............120 L/min at 20 680 kPa, 170 bar, at 2000 r/min
(31.6 U.S. gpm at 2500 psi at 2000rpm)
Low pressure pump (loader pump farthermost from transmission) ...86 L/min at 20 680 kPa, 170 bar, at 2000 r/min
(22.5 U.S. gpm at 2500 psi at 2000rpm)
Rotation ................................................................................................. Clockwise as seen from the end of the shaft
Special torques
Pump end cover bolts ..................................................................................................165 Nm (121.5 pound-feet)
Pump housing plug ........................................................................................................127 Nm (93.5 pound-feet)
Control piston plug ..............................................................................................................90 Nm (66 pound-feet)
PREPARING THE EQUIPMENT PUMP FOR USE

Do the following procedure any time you install a new 4. Repeat Step 3 for three minutes.
or overhauled equipment pump:
5. Increase the engine speed to full throttle and
1. Start and run the engine at half throttle for three repeat Steps 3 and 4.
minutes.
6. Stop the engine and check for leaks.
2. With the engine running at half throttle, move the
7. Replace the hydraulic filter.
bucket control lever into roll back position. Hold
the bucket control lever in this position until the
bucket stops moving.
3. Hold the bucket control lever in the roll back
position for five seconds. Then put the bucket
control lever in the NEUTRAL position for five
seconds.

Copyright
8004-4
EQUIPMENT PUMP
7 8 9
6 5
5 4
4
3
10
2 11
1
12 24
13 23
22
21
20
19
18
17
15
14 16
30
29
15 28
27
26
25
BC06F550
1. SNAP RING 11. TAPERED BEARING 21. PRESSURE PINS

2. SEAL 12. BEARING RACE 22. BACKUP PLATE
3. MAIN BODY 13. SHIM 23. SPRING
4. O-RING 14. SPRING 24. SNAP RING
5. PLUG 15. HALF BEARING 25. PORT PLATE
6. CONTROL VALVE 16. SWASH PLATE 26. SHIM
7. CAP SCREW 17. PISTONS 27. TAPERED BEARING
8. PISTON ROD 18. RETAINING PLATE 28. BEARING RACE
9. CONTROL PISTON 19. BALL 29. DOWEL PIN
10. SHAFT 20. CYLINDER 30. END COVER

Copyright
8004-5
Disassembly STEP 3
STEP 1
Remove all dirt, oil, and grease from the exterior of
the equipment pump.
STEP 2
BC06F552
Remove the control valve.
STEP 4
BC06F551
Put alignment marks on the end cover and housing.
BC06F553
Remove the four bolts.

Copyright
8004-6
STEP 5 STEP 6
BC06F555
BC06F554
Remove the end cover. Use a suitable bearing race puller and pull the
bearing race from the end cover.
NOTE: Watch for the flow plate, it can be stuck to
either the end cover or pump body. NOTE: Do not damage the sealing surfaces.

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8004-7
STEP 7 STEP 9
BC06F558
Remove plug, pull control piston using a suitable tool

as shown.
NOTE: Do not use a magnet to pull the piston.
STEP 10
BC06F556
Remove the bearing and shim.
STEP 8
BC06F559
Remove the piston rod and swash plate. Turn the

swash plate slightly to break it free from the bearings.
BC06F557
Remove the rotary group from the housing in a

horizontal position.

Copyright
8004-8
STEP 11 STEP 14
BC06F560
Remove the bearing and spring.
STEP 12
BC06F563
Use a suitable bearing race puller and pull the

bearing race from the housing.
STEP 15
BC06F561
Remove the shaft and bearing.
STEP 13
BC06F564
Remove the shim and plug.
BC06F562
Remove the retaining ring an seal.

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8004-9
Inspection STEP 19
STEP 16
Clean all parts in cleaning solvent. Be careful not to
remove the alignment marks made during
disassembly.
STEP 17
BC06F567
Check the bearing surface.
STEP 20
BC06F565
Check for wear on the splines, seal areas for

grooves, bearing areas for scaring, and key set.
STEP 18
BC06F568
Check that the retaining plate is free of grooves and

that there is no sign of wear.
STEP 21
BC06F566
Check the surface that the pistons contact for

grooves and scaring.
BC06F569
Check the sliding surface for scratches or metal

deposits, check the tightness of the cup on the
piston.
NOTE: If a piston needs to be replaced, all of the
pistons must be replaced.

Copyright
8004-10
STEP 22 STEP 24
BC06F572
BC06F570
Check the cylinder bores and splines for damage. Check cylinder surface for grooves, wear, embedded
particles. Check flow plate for scratches or wear.
STEP 23
STEP 25
BC06F571
BC06F573
Check ball for grooves and wear.
Check mounting surface for the flow plate for
damage.

Copyright
8004-11
Assembly STEP 27
STEP 26
BC06F574 BC06F575
Install the plug in the housing and tighten to 127 Nm Put the shaft and bearing in the housing.
(93.5 pound-feet). Install shim and press in the
bearing race. STEP 28
BC06F576
Press in a new race into the end cover.

Copyright
8004-12
STEP 29 STEP 31
BC06F579
Install the seal and retaining ring.
STEP 32
BC06F577
Install the end cover, 4 bolts and hand tighten.
STEP 30
BC06F578
A bearing pre load of 0.05 mm (0.002 inch) must be

obtained, add remove shims from bearing as
required.
BC06F580
Put new bearings in the housing. Install the reaction

spring.

Copyright
8004-13
STEP 33 STEP 34
BC06F582
Install the piston into the housing with flat surface

out. Lubricate the O-ring and install the plug, tighten
the plug to 90 Nm (66 pound-feet).
STEP 35
BC06F581
Install the swash plate into the housing, work the

swash plate from side to side to seat it in the
bearings and spring. Install the piston rod.
BC06F583
Use grease to hold the pressure pins into position,

install the spacer, spring and snap ring.

Copyright
8004-14
STEP 36 STEP 39
BC06F584
Use a suitable compressor, compress the spring and

install the snap ring.
STEP 37
BC06F585 BC06F587
Place the ball onto the pressure pins, install the Hold the pistons in the rotating housing using an
pistons into the retaining plate. O-ring, install the rotating group into the housing,
remove the O-ring.
STEP 38
BC06F586
Lubricate the piston and retaining plate with clean oil,

install the piston into the rotating housing.

Copyright
8004-15
STEP 40 STEP 41
BC06F588
Use the shim that was required for the bearing pre
load in step 30. Install the shim and bearing onto the
shaft.
BC06F589
Install a new O-ring on the end cover, place the flow

plate onto the rotating group with aligning notch up.
Place the end cover onto the housing, make sure
that the aligning pin in the end cover aligns with the
slot in the flow plate.

Copyright
8004-16
STEP 42 STEP 43
BC06F591
Use new O-rings, install and tighten the control valve.
BC06F590
Instal and tighten the four bolts to 165 Nm

(121.5 pound-feet).

Copyright
Section
8005
LOADER CONTROL VALVE
8005

Copyright
8005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Copyright
8005-3
SPECIFICATIONS
Manufacturer .................................................................................................................................................. Rexroth
Special Torques
End plate mounting bolts..................................................................................................70 Nm (51.5 pound feet)
Pressure relief, flow limit, and pilot pressure reducing valves.................. 20 to 25 Nm (177 to 221 pound inches)
Allen head plugs..............................................................................................................240 Nm (177 pound feet)
Allen head locking screw................................................................................................100 Nm (73.7 pound feet)
Allen head cover screws (short) .................................................................................. 10.4 Nm (92 pound inches)
Allen head cover screws (long) ........................................................................................ 6 Nm (53 pound inches)
Anticavitation valves.......................................................................................................100 Nm (73.7 pound feet)
Combination anticavitation and circuit relief .................................................................200 Nm (147.5 pound feet)
Main relief valve pressure settings (XT and Z-Bar) ............................................... 248 to 252 bar (3596 to 3654 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (XT and Z-Bar) .......................................................................................290 bar (4206 psi)
Bucket A port (XT and Z-Bar) ....................................................................................................152 bar (2205 psi)
Bucket B port (XT and Z-Bar) ....................................................................................................290 bar (4206 psi)

Copyright
8005-4
4
3
5
22
6
6 7
21
6
20
19 8
18
17
6 9
16
10
11
15 14
8
12 12
13
BS03C033
1. BOLT 7. LOAD SENSE SHUTTLE CHECK 13. FLOAT SOLENOID 18. LOAD CHECK
8. ANTICAVITATION AND CIRCUIT
2. WASHER 14. PLUG 19. FLOW LIMIT VALVE
RELIEF
15. REGENERATION CHECK
3. LOCKING SCREWS 9. LOAD SENSE BLEED DOWN ORIFICE 20. PRESSURE RELIEF VALVE
VALVE
4. PLATE 10. FLOW COMPENSATOR SPOOL 16. LOCKING SCREW 21. CONE
5. REGENERATION
11. HOUSING 17. SPRING 22. LOCKING SCREW
RELIEF VALVE
6. O-RINGS 12. PLUG
2 SPOOL VALVE HOUSING CONFIGURATION

Copyright
8005-5
27
26
25
24
23
6 28
31 29
30
6
6
33 33 32
34
31
6
23 24
24 23
34 6
35
32
30
29
BC06F593
6. O-RINGS 27. BOLT 32. BOLT

23. SPRING RETAINER 28. PISTON 33. COVER
24. SPRING 29. CAP NUT 34. ADJUSTING ROD
25. SPRING 30. JAM NUT 35. SPOOL
26. COVER 31. PISTON
2 SPOOL VALVE SPOOL CONFIGURATION

Copyright
8005-6
37
36
37
BS03C036
36. HOUSING 37. ANTICAVITATION AND CIRCUIT RELIEF

3 SPOOL MOUNTING CONFIGURATION

Copyright
8005-7
38
39
BS03C035
38. NUT 39. STUD

4 SPOOL MOUNTING CONFIGURATION

Copyright
8005-8
31 29
30
33
34
6 6
23
24
23 32
35
33 23
31 24
6
6
34
29
30 32
BS03C037
3 AND 4 SPOOL VALVE SPOOL CONFIGURATION
6. O-RINGS 31. PISTON

23. SPRING RETAINER 32. BOLT
24. SPRING 33. COVER
29. CAP NUT 34. ADJUSTING ROD
30. JAM NUT 35. SPOOL

Copyright
8005-9
DISSASEMBLY
STEP 1 STEP 7
Remove valve from machine, see section 8001. Remove pressure relief valve (20).
STEP 2 STEP 8
Remove bolts (27), cover (26), springs (24 and 25), Remove flow limit valve (19).
and spring retainer (23).
STEP 9
STEP 3 Remove locking screw (16), spring (17), and cone
Remove bolts (32), covers (33), spring (24), and (18).
spring retainer (23).
STEP 10
STEP 4 Remove regeneration check valve (15).
Use wooden dowel or brass drift and push spools
(35) from housing (11). STEP 11
IMPORTANT: Do not force spools from housing, if Remove locking screw (14).
spool binds work back and forth until spool comes
out freely. STEP 12
NOTE: Repeat steps 3 and 4 for a 3 and 4 spool Remove load sense shuttle check valve (7).
valve configuration.
STEP 13
STEP 5 Remove locking screws (12).
Remove anticavitation valves (5, 8, 10, and 13).
STEP 14
NOTE: Repeat step for a 3 and 4 spool
Remove pilot pressure reducing valve (9).
anticavitation valves (37).
STEP 15
STEP 6
Remove bolts (1) and washers (2), remove plate (4)
Remove locking screw (22) and cone (21).
from housing (11).
NOTE: For 4 spool configuration remove nut (38)
from stud (39), remove housings (36) from housing
(11).

Copyright
8005-10
STEP 16 STEP 18
2
1
2
1
1
1
BS03C025 BS03C027
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RING

Remove and discard O-rings and thrust rings from Remove and discard O-rings and thrust ring from
pilot pressure reducing valve (9). locking screw (14).
STEP 17
2 STEP 19
1
2
1
1
3
1 1
BS03C026 2
1. O-RINGS 2. THRUST RINGS BS03C028
Remove and discard O-rings and thrust rings from 1. O-RINGS 2. THRUST RING 3. SPOOL SEAL
flow limit valve (19).
Remove and discard O-rings, thrust ring, and spool
seal from anticavitation valve (5).

Copyright
8005-11
STEP 20
1
1
2
BS03C029
1. O-RINGS 2. THRUST RINGS

Remove and discard O-rings and thrust rings from pressure relief valve (20).
STEP 21
1
2
1
2
BS03C030

Remove and discard O-rings and thrust rings from anticavitation and pressure relief valves (10).

Copyright
8005-12
STEP 22
BS03C031
1. O-RINGS 2. COIL
Remove and discard O-rings and thrust rings from anticavitation valve (13).

Copyright
8005-13
STEP 23
3
4
2 1
1
1
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Remove and discard O-rings and thrust rings from anticavitation and circuit relief valves (8 and 37).

Copyright
8005-14
INSPECTION
1. Discard all O-rings, thrust rings, and spool seals. 4. Check the parts of the pressure relief valve,
anticavitation valves, and the anticavitation and
2. Clean all parts in cleaning solvent.
circuit relief valves. Use new parts as necessary.
3. Check the spools and the spool bores for
Inspect the other parts of the control valve. If any of
damage and wear.
the parts are damaged, install new parts.
ASSEMBLY
STEP 1
3
4
A
2 1
1 See Note
1
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Install new O-rings and thrust rings on anticavitation and circuit relief valves (8 and 37). Torque relief valve (A) into
anticavitation valve to 200 Nm (147.5 pound feet).
NOTE: Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is
in direction of arrow.

Copyright
8005-15
STEP 2
A
1
BS03C031
1. O-RINGS 2. COIL
Install new O-rings and thrust rings on anticavitation valve (13). Hand tighten coil nut (A).
STEP 3
1
2
1
2
1 A
BS03C030

Install new O-rings and thrust rings on anticavitation and pressure relief valves (10). Torque cap (A) to 100 Nm
(73.7 pound feet).

Copyright
8005-16
STEP 4
1
1
2
BS03C029

Install new O-rings and thrust rings on pressure relief valve (20).

Copyright
8005-17
STEP 5 STEP 8
2 1
1
1
3
1 1
2
BS03C025 BS03C028
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RING 3. SPOOL SEAL

Install new O-rings and thrust rings on pilot pressure Install new O-rings, thrust ring, and spool seal on
reducing valve (9). anticavitation valve (5).
STEP 6 STEP 9
Install and torque regeneration check valve (15) to
2
100 Nm (73.7 pound feet).
STEP 10
Install and torque locking screw (14) to 100 Nm
2 (73.7 pound feet).
1
1 STEP 11
Install and tighten load sense shuttle check valve (7).
STEP 12
BS03C026 Install and torque locking screws (12) to 240 Nm
1. O-RINGS 2. THRUST RINGS (177 pound feet).
Install new O-rings and thrust rings on flow limit valve
(19). STEP 13
Install and torque pilot pressure reducing valve (9) to
STEP 7 60 Nm (44 pound feet).
STEP 14
1 Install new O-rings on housing (11). Install plate (4),
bolts (1) and washers (2), onto housing (11). Torque
2 bolts to 70 Nm (51.5 pound feet).
1 NOTE: For 4 spool configuration install new O-rings

between housings (36) and housing (11), install nuts
(38) on studs (39). Torque nuts to 70 Nm (51.5
pound feet).
STEP 15
BS03C027 Install anticavitation valves (5, 10, and 13) and
1. O-RINGS 2. THRUST RING torque to 100 Nm (73.7 pound feet).
Install new O-rings and thrust ring on locking screw NOTE: Repeat step for a 3 and 4 spool
(14). anticavitation valves (37).

Copyright
8005-18
STEP 16 Circuit Relief Pressure Test
Install anticavitation valves (8) and torque to 200 Nm
(147.5 pound feet). STEP 1
Connect the hand pump to the port for anticavitation
STEP 17 and circuit relief valves (21).
Install and torque flow limit valve (19) to 20 to 25 Nm
NOTE: Repeat steps for machines that are
(177 to 221 pound inches).
configured with a 3 or 4 spool valve.
STEP 18 STEP 2
Install cone (18), spring (17), locking screw (16).
Make sure that the hand pump is full of hydraulic oil
Torque locking screw to 100 Nm (73.7 pound feet).
and that the temperature of the oil is approximately
21C (70F).
STEP 19
Install cone (21) and locking screw (22). Torque STEP 3
locking screw to 40 Nm (30 pound feet).
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
STEP 20 be sure of the reading.
Lubricate spools with hydraulic oil and push spools
(35) into housing (11). STEP 4
IMPORTANT: Do not force spools into housing. Compare the reading to the specifications on Page 3.
STEP 21 STEP 5
Install spring retainers (23), springs (24), covers (33), If the pressure is not correct, adjust the circuit relief
and bolts (32). Torque bolts to 10.4 Nm (92 pound valve.
inches).
NOTE: Repeat steps 18 and 19 for a 3 and 4 spool Circuit Relief Adjustment
valve configuration.
STEP 1
STEP 22 Loosen the lock nut. Turn the adjustment screw
Install spring retainers (23), spring (24 and 25), cover clockwise to increase the pressure or
(26), and bolts (27). Torque bolts to 6 Nm (53 pound counterclockwise to decrease the pressure.
inches). NOTE: One turn of the adjusting screw will change
NOTE: Prior to installation in the machine, circuit the pressure approximately 138 bar (2000 psi).
reliefs can be tested.
STEP 2
STEP 23 Check the pressure again. Repeat the adjustment as
Install valve in machine, see section 8001. necessary.
STEP 24
Check loader limit pressure, see section 8002.

Copyright
Section
8006
CYLINDERS
8006

Copyright
8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Copyright
8006-3
SPECIFICATIONS
Approximate weight
Lift Cylinder...........................................................................................................................142.2 kg (313.5 pounds)
Bucket Cylinder .......................................................................................................................199.2 kg (439 pounds)
SPECIAL TORQUES
Gland Bolts Bucket Cylinder.......................................................................420 to 500 Nm (310 to 368.8 pound-feet)
Screw in Gland for Lift Cylinders ...................................................................135 to 542 Nm (100 to 400 pound-feet)
Piston Bolt for Lift Cylinders ...............................................................2830 to 3220 Nm (2087 to 2374.9 pound-feet)
Lock Screw for Lift Cylinders ............................................................................................. 2.3 Nm (20 pound-inches)
SPECIAL TOOLS
Torque Multiplier......................................................................................................................................... CAS-1039

Copyright
8006-4
LIFT CYLINDER
Disassembly Inspection
1. Clean exterior of cylinder. If hoses were removed 1. Clean all parts in cleaning solvent. Use only lint
with cylinder, remove hoses from cylinder. free cloths for cleaning and drying.
2. Fasten tube (1) in an acceptable repair stand or 2. Check to be sure that piston rod (13) is straight.
other holding equipment. Do not damage tube If piston rod is not straight, replace it with a new
(1). piston rod.
3. Loosen and remove self-tapping screw (12). 3. Shine a light inside tube (1) and check for deep
grooves and other damage. If there is any
4. Use a spanner wrench to loosen and remove
damage to tube, replace with a new tube.
gland (4) from tube (1).
4. Remove any small scratches on piston rod (13)
5. Pull piston rod (13) straight out of tube (1) to
or inside tube (1) with emery cloth of medium
prevent damage to tube.
grit. Use emery cloth with a rotary motion.
6. Fasten piston rod eye or yoke in a vise and put a
5. Inspect bushings (2) in tube eye. Replace as
support under piston rod (13) near piston (15).
required.
Put a shop cloth between support and piston rod
to prevent damage to piston rod. 6. Inspect gland (4) for rust. Clean and remove rust
as necessary.
7. Use a torque multiplier, CAS-1039, to loosen and
remove bolt (14) that fastens piston (15) to piston 7. Inspect gland end of tube (1) for sharp edges
rod (13). that may cut gland O-ring (11) and remove as
necessary.
8. Remove piston (15) from piston rod (13).
8. Inspect piston (15) for damage and wear. If
9. Remove gland (4) from piston rod (13).
piston is damaged or worn, replace with a new
10. Remove and discard seal (16), ring (17), and piston.
wear ring (18) from piston (15).
11. Remove and discard O-ring (10), backup ring (9),
O-ring (11), wiper (5), rod seal (6), buffer seal
(7), and bushing (8) from gland (4).

Copyright
8006-5
13
5
6
7
4
8
11
9
10
15
12
17
16
18
14
1
3
2
2
3
BC05J002
1. TUBE 6. ROD SEAL 11. O-RING 16. SEAL

2. BUSHING 7. BUFFER SEAL 12. SCREW 17. RING
3. WIPER 8. BUSHING 13. ROD 18. WEAR RING
4. GLAND 9. BACKUP RING 14. BOLT
5. WIPER 10. O-RING 15. PISTON
LIFT CYLINDER

Copyright
8006-6
Assembly 17. Install a new ring (17) in the other groove on the
outside of the piston (15).
NOTE: If a new gland is being used, put part number
of cylinder on new gland. 18. Install a new seal (16) on top of ring (17).
1. Install bushing (8) in gland (4). 19. Fasten tube (1) in an acceptable repair stand or
other holding equipment. Be careful to prevent
2. Install rod seal (6) in gland (4). Rod seal is to be damage to tube.
installed so that lips of seal are toward bushing
(8). Rod seal (6) can be difficult to install. 20. Lubricate inside of the tube (1) and piston (15)
with clean oil.
3. Install buffer seal (7) in gland (4). The side of
buffer seal with groove must be toward bushing 21. Push piston (15) straight into tube (1).
(8). 22. When the piston (15) is in smooth part of tube
4. Install a new wiper (5) in gland (4). Lips of wiper (1), start gland (4) into tube.
must be toward outside end of gland (4). 23. Lubricate O-rings (10 and 11) on gland (4) with
5. Install a new O-ring (11) in groove on OD of clean oil.
gland (4). 24. Turn gland (4) into tube (1). Tighten gland to a
6. Install a new backup ring (9) in groove on OD of torque of 135 to 542 Nm (100 to 400 pound-feet).
gland (4). If both sides of backup ring are not flat, 25. If the original parts are being assembled:
side that is not flat must be toward small end of
gland (4). A. Tighten gland to a torque of 135 to 542 Nm
(100 to 400 pound-feet).
7. Install a new O-ring (10) next to backup ring (9)
in groove on outside of gland (4). O-ring must be B. Install and tighten self-tapping screw (12) to a
toward small end of gland. torque of 2.3 Nm (20 inch-pounds).
8. Fasten piston rod (13) eye or yoke in vise. C. If, after tightening gland, the self-tapping
screw (12) holes are not aligned, a new hole
9. Remove any marks and sharp edges on chamfer for self-tapping screw must be drilled. See
at end of piston rod (13). Make sure that piston Step 26.
rod is clean.
26. If a new gland (4) or a new tube (1) are being
10. Lubricate bore of gland (4) and piston rod (13) assembled:
with clean oil.
A. Tighten gland (4) to 135 to 542 Nm (100 to
11. Push gland (4) onto piston rod (13). If necessary, 400 pound-feet).
use a soft hammer to drive gland onto piston rod.
B. Use a No. 27 drill bit and drill a hole half in
12. Put a support below and near end of piston rod gland (4) and half in tube (1). Drill to a depth of
(13). Use a shop cloth between support and the 11 mm (7/16 inch). Do not drill within 13 mm
piston rod to prevent damage to piston rod. (1/2 inch) of a hole for gland wrench.
13. Start piston (15) onto piston rod (13). C. Install and tighten self-tapping screw (12) to a
14. Clean the threads on the end of the piston rod torque of 2.3 Nm (20 inch-pounds).
(13) and the threads of the bolt (14) using Loctite 27. If hoses were removed with cylinder, install new
cleaning solvent. Allow to dry. Apply Loctite 242 O-rings, if equipped, on hose fittings. Lubricate
to piston rod threads 6.3 mm (1/4 inch) from O-rings with clean oil. Install hoses.
open end of piston rod so that there is 13 mm
(1/2 inch) of Loctite 242 on piston rod threads.
DO NOT apply Loctite to first 6.3 mm (1/4 inch)
of piston rod threads.
15. Install bolt (14) into piston rod (13). Tighten bolt
to a torque of 2830 to 3220 Nm (2087 to 2374.9
pound-feet). A torque multiplier can be used to
help torque the bolt.
16. Install a new wear ring (18) in wide groove on
outside of piston (15).

Copyright
8006-7
BUCKET CYLINDERS
Disassembly Inspection
1. Clean the outside of the cylinder. If the hoses 1. Discard the parts that were removed from the
were removed with the cylinder, remove the piston and the gland.
hoses from the cylinder. 2. Clean all parts in cleaning solvent. Use only lint
2. Fasten the tube (1) in an acceptable repair stand free cloths for cleaning and drying.
or other holding equipment. Do not damage the 3. Check to be sure that the piston rod is straight. If
tube (1). the piston rod is not straight, replace it with a
3. Loosen and remove the cap screws (2) and new piston rod.
hardened washers (18) from the gland (3) and 4. Illuminate the inside of the tube for deep grooves
the tube (1). and other damage. If there is any damage to the
4. Pull the piston rod (4) straight out of the tube (1) tube, replace it with a new tube.
to prevent damage to the tube (1). 5. Remove any small scratches on the piston rod or
5. Fasten the piston rod eye or yoke in a vise and inside the tube with emery cloth of medium grit.
put a support under the piston rod (4) near the Use the emery cloth with a rotary motion.
piston (7). Put a shop cloth between the support 6. Inspect the bushings in the piston rod eye or
and the piston rod (4) to prevent damage to the yoke and the tube. Replace as required.
piston rod (4).
7. Inspect the gland for rust and clean and remove
6. Remove the retaining ring (10) that fastens the rust as necessary.
pin (11) in the piston (7) and piston rod (4).
8. Inspect the gland end of the tube for sharp edges
7. Remove the pin (11) from the piston (7) and the that will cut the gland O-ring and remove as
piston rod (4). necessary.
8. Turn the piston (7) off the piston rod (4) and 9. Inspect the piston for damage and wear. If the
remove the piston (7). piston is damaged or worn, replace it with a new
9. Remove the gland (3) from the piston rod (4). piston.
10. Remove the seal (6) from the OD of the piston
(7).
11. Remove the wear ring (5) from the OD of the
piston (7).
12. Remove the backup rings (8) and the O-ring (9)
from the ID of the piston (7).
13. Remove the O-ring (16), backup ring (15), wiper
(12), wide seal (13), narrow seal (14), and
bushing (17) from the gland (3).

Copyright
8006-8
19
20
19
4
2
18
3
17
15
12
16 13
11 8 14
8 9
7
6
5 1
10
19
20
19
BC05M026
1. TUBE 7. PISTON 12. WIPER 17. BUSHING

2. CAP SCREW 8. BACKUP RING 13. WIDE SEAL 18. HARDENED WASHER
3. GLAND 9. O-RING 14. NARROW SEAL 19. SEAL
4. PISTON ROD 10. RETAINING RING 15. BACKUP RING 20. BUSHING
5. WEAR RING 11. PIN 16. O-RING
6. SEAL
BUCKET CYLINDER

Copyright
8006-9
Assembly 11. Install a new backup ring (8) in the groove in the
ID of the piston (7). If both sides of the backup
NOTE: If a new gland is being used, put the part ring (8) are not flat, the side that is not flat must
number of the cylinder on the new gland. be toward the O-ring (9).
1. Install the bushing (17) in the gland (3), refer to 12. Install a new O-ring (9) in the groove in the ID of
illustration on page 8. the piston (7) next to the backup ring (8).
2. Install the wide seal (13) in the gland (3). The 13. Install the other new backup ring (8) in the
wide seal (13) is to be installed so that the lips of groove in the ID of the piston (7) next to the
the wide seal (13) are toward the bushing (17). O-ring (9). If both sides of the backup ring (8) are
The wide seal (13) can be difficult to install. not flat, the side that is not flat must be toward
3. Install a new wiper (12) in the gland (3). The lips the O-ring (9).
of the wiper (12) must be toward the outside end 14. Lubricate the ID of the piston (7) with clean oil.
of the gland (3).
15. Start the piston (7) onto the piston rod (4). Turn
4. Install the narrow seal (14) in the gland (3). The the piston (7) onto the piston rod (4) until the
side of the narrow seal (14) with the groove must piston (7) is seated against the shoulder of the
be toward the bushing (17). piston rod (4).
5. Install a new backup ring (15) in the groove on 16. If none of the holes in the piston (7) align with the
the outside of the gland (3). If both sides of the holes in the piston rod (4), turn the piston (7)
backup ring (15) are not flat, the side that is not counterclockwise until one of the holes in the
flat must be toward the small end of the gland piston (7) aligns with one of holes in the piston
(3). rod (4). Do not turn the piston (7) more than 90
6. Install the O-ring (16) next to the backup ring (15) degrees.
in the groove on the outside of the gland (3). The
O-ring (16) must be toward the small end of the 7
gland (3).
11
7. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (4). Make 10
sure that the piston rod (4) is clean.
8. Lubricate the bore of the gland (3) and the piston
rod (4) with clean oil.
9. Push the gland (3) onto the piston rod (4). If
necessary, use a soft hammer to drive the gland
(3) onto the piston rod (4). 4
10. Put a support below and near the end of the
GS98J804
piston rod (4). Use a shop cloth between the
support and the piston rod (4) to prevent damage PISTON AND PISTON ROD HOLE ALIGNMENT
to the piston rod (4). 17. Install the pin (11) in the piston (7) and the piston
rod (4).
18. Install the retaining ring (10) in the pin (11).

Copyright
8006-10
19. Install a new wear ring (5) in the wide groove on 27. Tighten the cap screws (2) in the sequence
the OD of the piston (7). shown. Torque to 420 to 500 Nm (310 to 368.8
20. Install a new seal (6) in the groove on the OD of pound-feet).
the piston (7).
21. Fasten the tube (1) in an acceptable repair stand
or other holding equipment. Be careful to prevent
damage to the tube (1).
22. Lubricate the inside of the tube (1) and the
outside of the piston (7) with clean oil.
23. Push the piston (7) straight into the tube (1).
24. Lubricate the O-ring (16) on the gland (3) with
clean oil.
25. Push the gland into the tube (1) and align the
holes in the tube (1).
26. Install the cap screws (2) and hardened washers
(18).
BC05M027
TUBE AND GLAND HOLE ALIGNMENT

Copyright
8006-11
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS
Removal
1. Put piston tube (4) in a press.
2. Use an acceptable driver to press wipers (1) and
bushings (2) out of piston tube (4) eye.
3
3. Clean bore for bushings (2) in tube (4) eye.
1
Installation
4
1. Use an acceptable driver to press new bushings
(2) into tube (4) eye. Bushings shall be recessed
8 mm (0.315 inch) in tube eye.
2
2. Use an acceptable driver to install wipers (1) until
flush with tube (4) eye. The lips of wipers must 1
be toward outside of bore. 2
BS01C003
1. WIPER 3. PISTON ROD YOKE

2. BUSHING 4. TUBE
BUSHING AND WIPER REMOVAL AND REPLACEMENT
LIFT CYLINDERS

Copyright
8006-12
REPLACING BUSHINGS FOR THE BUCKET CYLINDER
Removal
3
1. Put piston rod eye (3) in a press.
2. Use an acceptable driver to press wipers (1) and
bushing (2) out of piston rod eye (3). 2
3. Put tube (4) in a press. 1 1
4. Use an acceptable driver to press bushings (2) 2
out of tube (4) eye.
5. Clean bore for bushings (2) in piston rod eye (3)
and tube (4) eye.
4
1
Installation 2
(2) into piston rod eye (3) until recessed 8 mm
(0.315 inch).
2. Use an acceptable driver to install wipers (1) until
flush with piston rod eye (3). The lips of the 2
wipers (1) must be towards outside of bore.
(2) into tube (4) eye until recessed 8 mm (0.315
inch).
1
4. Use an acceptable driver to install wipers (1) until BS03B201
flush with tube (4) eye. The lips of wipers (1)
1. WIPER 3. PISTON ROD EYE
must be towards outside of bore. 2. BUSHING 4. TUBE
BUSHING AND WIPER REMOVAL AND REPLACEMENT
BUCKET CYLINDERS

Copyright
Section
8007
COUPLER SOLENOID LOCKING VALVE
8007

Copyright
8007-2
TABLE OF CONTENTS
coupler solenoid locking valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Copyright
8007-3
COUPLER SOLENOID LOCKING VALVE
Disassembly STEP 11
Install solenoid (2) on valve cartridge (3).
STEP 1
Clean exterior of valve. STEP 12
Install nut (1) to secure solenoid (2).
STEP 2
Remove nut (1) and solenoid (2) from valve cartridge
(3). 1
STEP 3
Remove valve cartridge (3) from valve housing (7).
2
STEP 4
Remove and discard all O-rings (4 and 5) and
back-up rings (6).
Cleaning and Inspection

STEP 5
Immerse valve cartridge (3) and valve housing (7) in
3
cleaning solvent and agitate cleaning solvent. WEAR
EYE PROTECTION WHEN USING COMPRESSED
AIR. Use compressed air to remove foreign matter
from interior of valve cartridge and housing and to 4
ensure that all passage ways and bores are clear.
6
STEP 6 5
Check valve cartridge for (3) for cracks, breaks, 6
chipping, or other damage. Replace if any of these 6
conditions are seen.
5
6
STEP 7
6
Check bores in valve housing (7) for deep scratches, 5
gouges, and other damage. Replace valve if any of
these conditions are seen.
7 6
STEP 8
Connect an ohmmeter across terminals of solenoid
(2) connector. Replace solenoid (2) and valve
cartridge (3) if ohmmeter indicates short or open
circuit.
Assembly GS98J818
1. NUT 5. O-RING
STEP 9
2. SOLENOID 6. BACKUP RING
Install new O-rings (4 and 5) and back-up rings (6) as 3. VALVE CARTRIDGE 7. VALVE HOUSING
shown. 4. O-RING
STEP 10
Lubricate O-rings (4 and 5) using clean oil then install
valve cartridge (3) in valve housing (7).
Copyright
8007-4
NOTES

Copyright
Section
8013
8013
RIDE CONTROL ACCUMULATOR

Copyright
8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Copyright
8013-3
SPECIFICATIONS
Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 8
Ride Control Accumulator Fluid Capacity............................................................................. 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure...........................................................248.4 bar (3600 psi)
ACCUMULATOR SPECIAL TORQUES

Accumulator Gas Charging Valve Cap.................................................................................13.6 Nm (10 pound-feet)
Gas Charging Valve ............................................................................................88 to 102 Nm (65 to 75 pound-feet)
Cap screws for the protection bracket .......................................................... 54 to 61 Nm (480 to 540 pound-inches)
Gland .............................................................................................................163 to 176 Nm (120 to 130 pound-feet)
SPECIAL TOOLS
94L95 B786441M
CAS10899 NITROGEN ACCUMULATOR CHARGING KIT CAS1456 GLAND WRENCH

Copyright
8013-4
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR
C E
D B A
94L95
CAS10899 NITROGEN CHARGING KIT
1. Use the CAS-10899 Nitrogen Charging Kit to 7. Turn the T-handle inward on valve F to engage
discharge the accumulator, refer to the the pin in the valve stem.
illustration above. The tool must be disconnected
8. Open valve D and check the charge pressure on
from the nitrogen tank.
gauge E.
2. Close valves B, C and D.
9. To discharge the accumulator, partially open
3. Adjust the regulator A to the minimum pressure valve B. The accumulator charge will bleed down
setting by turning the knob counterclockwise. through the regulator.
4. Turn the T-handle on valve F fully out. 10. Once the accumulator is fully discharged,
disconnect valve F from the valve stem.
5. Remove the guard and valve assembly cap from
the accumulator. 11. The accumulator can now be disassembled.
6. Connect valve F to the valve stem on the
accumulator.

Copyright
8013-5
ACCUMULATOR
Disassembly Assembly
NOTE: Refer to Section 8001 for the proper 1. Fasten the body (1) in a vise. Be careful not to
procedure for the removal of the ride control damage the body (1). Refer to the illustration on
accumulator. page 6.
WARNING: DO NOT attempt to 2. Install a new wear ring (5), O-ring (7) and backup
disassemble any accumulator until the ring (6) on the piston (4).
nitrogen charge is properly discharged. 3. Lubricate the bore of the body (1) and the piston
SM386 (4) with clean oil.
1. Fasten the body (1) in a vise. Be careful not to 4. Start the piston (4) into the body (1), round
damage the body (1), refer to the illustration on surface first. Then push the piston (4) farther into
page 6. the body (1).
2. Remove the screws (9) and guard (11) from the
NOTE: The piston (4) must be installed squarely and
body (1).
slowly into the body (1). Once the piston (4) is started
3. Remove the pressure valve (12) from the straight into the bore of the body (1), use a hammer
body (1). and wood block to gently tap the piston into the
4. Remove and discard the O-ring (10) from the polished area of the bore. Keep force on the piston
pressure valve (12). (4) while tapping into the bore or damage may occur
to the O-ring.
5. Loosen and remove the cap (8) from the body
(1). 5. Install and tighten the cap (8) into the body (1).
6. Loosen and remove the gland (3) from the body 6. Install new seals (2) on the gland (3).
(1).
7. Lubricate the seals (2) with clean oil and start the
7. Remove the piston (4) from the body (1). gland (3) into the body (1).
8. Remove and discard the wear ring (5), O-ring (7)
8. Tighten the gland (3).
and the backup ring (6) from the piston (4).
9. Remove the seals (2) from the gland (3). 9. Install a new O-ring (10) on the pressure valve
(12).
Inspection 10. Install the pressure valve (12) in the body (1).
1. Clean body (1), gland (3), cap (8) and piston (4) 11. Install the guard (11), screws (9) in the body (1).
in cleaning solvent, refer to the illustration on 12. Charge the accumulator with dry nitrogen
page 6. according to instructions on page 7.
2. Inspect the piston (4) for cracks, burrs or other
damage. WARNING: Use only nitrogen when
charging the accumulator. DO NOT use air
3. Inspect the bore of the body (1) for scratches or or oxygen that will cause an explosion.
scoring using a light. SM115A
NOTE: Minor scratches or scoring in the bore of the

body (1) can be removed using crocus cloth.
4. Inspect the pressure valve (12) and replace as
needed.

Copyright
8013-6
1 2 5 6 7 9
8
3 4
10 11
12
9
BS01B224
1. BODY 5. WEAR RING 9. SCREW

2. SEALS (2) 6. BACKUP RING 10. O-RING
3. GLAND 7. O-RING 11. GUARD
4. PISTON 8. CAP 12. PRESSURE VALVE
RIDE CONTROL ACCUMULATOR ILLUSTRATION

Copyright
8013-7
CHARGING THE ACCUMULATOR WITH NITROGEN
6 5
4 3
GS98N801
1. VALVE C 4. VALVE B
2. TO NITROGEN TANK 5. VALVE D
3. VALVE A 6. TO ACCUMULATOR
NITROGEN CHARGING KIT CAS10899
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A
WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406
WARNING: Do not expose the accumulator to temperatures above 49 C (120 F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407
IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer to the above illustration.
IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during
high pressure (10 bar/150 psi and above) applications.

Copyright
8013-8
1. Close the shutoff valve A by turning it all the way 12. Open the shutoff valve A on the nitrogen supply
to the left (counterclockwise), refer to the tank. While observing the pressure on the gauge,
illustration on page 7. slightly open the needle valve on the
accumulator charge hose. By regulating the
2. Open valve B by turning it out all the way to the
needle valve, fill the accumulator to pressure
left (counterclockwise).
according to temperature chart below. Close the
3. Close valve C by turning it all the way to the right needle valve. Close the shutoff valve A on the
(clockwise). nitrogen supply tank.
4. Close the gauge valve D by turning it all the way TEMPERATURE CHARGE PRESSURE
to the right (clockwise). 10 C 50 F 1606 KPA 233 PSI
13 C 55 F 1634 KPA 237 PSI
5. Connect the charging hose to the nitrogen supply
16 C 60 F 1669 KPA 242 PSI
tank.
18 C 65 F 1696 KPA 246 PSI
6. SLOWLY turn valve A clockwise while watching 21 C 70 F 1724 KPA 250 PSI
the high pressure gauge. Stop turning valve A 24 C 75 F 1751 KPA 254 PSI
when the needle on the gauge reaches 31 bar 27 C 80 F 1779 KPA 258 PSI
(450 psi). 29 C 85 F 1813 KPA 263 PSI
32 C 90 F 1841 KPA 267 PSI
NOTE: If the needle goes over the needed pressure,
35 C 95 F 1868 KPA 271 PSI
quickly open and close valve D and check the
38 C 100 F 1896 KPA 275 PSI
pressure setting again.
The charging kit is now ready to be installed on the TEMPERATURE/CHARGE PRESSURE RIDE CONTROL
accumulator. ACCUMULATOR
13. Close valve B by turning to the right (clockwise).
7. Remove the two cap screws (9) and the
After a few minutes, check the accumulator for
protection bracket (11) from the body (1) on the
leakage.
accumulator, refer to the illustration on pages 6.
14. Back off the needle valve on the accumulator
8. Remove the valve cap from the pressure valve
end of the charging hose by turning it
(12) on the accumulator.
counterclockwise the maximum amount. This will
9. Back off the needle valve on the accumulator prevent nitrogen from escaping from the
end of the charging hose by turning it accumulator as the hose is removed. Remove
counterclockwise to the maximum amount. This the charging hose from the accumulator
prevents nitrogen from escaping from the pressure valve (12).
accumulator when the charging hose is attached
15. Install the valve cap onto the pressure valve (12)
to the accumulator gas charging valve.
on the accumulator.
10. Install the charging hose fitting onto the
16. Install the protection bracket (11) over the
accumulator pressure valve (12).
pressure valve (12) and secure it with cap
11. Tighten the needle valve by turning it clockwise. screws (9).
Slowly open the gauge valve D and observe the
17. Remove the charging hose from the nitrogen
reading on the gauge. This reading is the
supply tank.
nitrogen pressure level inside the accumulator.

Copyright
Section
8014
8014
RIDE CONTROL VALVE

Copyright
8014-2
TABLE OF CONTENTS
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Copyright
8014-3
RIDE CONTROL VALVE
9 11
10
8
7 13 12
14
15
6
5
4
3 16
2
1 17
BC05B015.
1. PLUG 6. SPRING 10. ACCUMULATOR DRAIN SCREW 14. POPPET

2. CAP SCREW 7. SPOOL 11. PLUG 15. ORFICE
3. BUSHING 8. PLUG 12. SOLENOID 16. VALVE BLOCK
4. SPRING CARRIER 9. PLUG 13. ORFICE 17. RELIEF VALVE
5. SPRING
Dissasembly STEP 8
Remove the pressure relief valve (17).
STEP 1
Remove ride control valve, refer to section 8001. Inspection
1. Discard all O-rings.
STEP 2
Remove plugs (1), (8), (9), and (11). 2. Clean all parts in cleaning solvent.
3. Check the spools and the spool bores for
STEP 3 damage and wear.
Remove the solenoid (12). 4. Check the parts of the pressure relief valve.
STEP 4 If any of the parts are damaged, install new parts.

Remove the spool (7) from the valve block (16).
STEP 5
Remove cap screw (2), bushing (3), spring carrier
(4), springs (5 & 6) from spool (7).
STEP 6
Remove orifice (13), poppet (14), and orifice (15).
STEP 7
Remove accumulator drain screw (10).

Copyright
8014-4
Assembly STEP 6
Install springs (5 &6), spring carrier (4), bushing (3),
STEP 1 cap screw (2) onto spool (7) and torque cap screw
Install new O-rings. (2) to 5.5 Nm (48.5 lb-in).
STEP 2 STEP 7
Install and torque pressure relief valve (17) to 50 Nm Install spool (7) into valve block (16).
(37 lb-ft).
STEP 8
STEP 3 Install and torque plug (1) to 270 Nm (199 lb-ft).
Install and torque accumulator drain screw (10) to
3.5 Nm (31 lb-in). Install the plug for accumulator STEP 9
drain screw and torque to 7 Nm (62 lb-in). Install plug (8) and torque to 140 Nm (103 lb-ft), plug
(9) and torque to 30 Nm (22 lb-ft), and plug (11) and
STEP 4 torque to 90 Nm (66 lb-ft).
Install and torque orifice (15) to 15 Nm (11 lb-ft),
install poppet (14), install and torque orifice (13) to STEP 10
15 Nm (11 lb-ft). Install the ride control valve in the machine, see
section 8001.
STEP 5
Install and torque solenoid valve to 12 Nm (106 STEP 11
lb-in). Test the ride control system, see section 8002.

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Section Title Section Number

Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001

Copyright 2007 CNH Italia S.p.A.

REMOVAL AND INSTALLATION OF HYDRAULIC

Copyright 2007 CNH Italia S.p.A.

87551879A Issued 1-07 Printed in E.C.

LOADER CONTROL VALVE

Relieve the pressure in the ride control accumulator

Loosen and remove the bolts and washers that

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1. GREEN WHITE GREEN 4. ORANGE BLACK GREEN 7. GREEN BLACK GREEN

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1. DUMP LINE 4. RAISE LINE RIGHT 6. LOWER LINE RIGHT

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Raise the loader arms and remove the safety link.

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REMOTE CONTROL VALVE

Open and remove the access panel.

Remove the front access panel.

Unlatch and open the window on the right hand side.

Disconnect the electrical connectors for the remote

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Connect the electrical connectors for the remote

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Install and close the access panel.

Position the access panel on the ROPS cab or the

Close the right hand window.

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1. PILOT TANK HOSE 4. ORANGE BLACK GREEN 7. GREEN WHITE GREEN

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1. PILOT TANK HOSE 1. PILOT TANK HOSE

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1. PILOT TANK HOSE 1. PILOT TANK HOSE

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Use a proper lifting device and secure a strap around

Tag and disconnect the hoses on each side of the lift

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Loosen and remove the bolt, washer and spacer that

Use a proper lifting device and position the lift

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BUCKET CYLINDER - Z-BAR LOADER

Removal STEP 108

Loosen and remove the two bolts that fasten the

Disconnect the proximity switch connector from the

Loosen and remove the two bolts that fasten the

Loosen and remove the two bolts that fasten the

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Loosen and remove the bolt, washer and spacer that

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Installation STEP 120

Connect the hoses to each side of the bucket

STEP 118 STEP 122

Install the pivot pin to the head end of the bucket

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STEP 125 STEP 128

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Removal STEP 138