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Service

Manual
G Series
S/N 527011001 & Above
S/N 527911001 & Above
S/N 527711001 & Above
S/N 527811001 & Above

EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6902734 (2-06) Printed in U.S.A. © Bobcat Company 2006
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.

CORRECT CORRECT CORRECT

B-10731a B-15954 B-15956


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

B-15967 B-15958 B-15955


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

B-15966 B-15951 B-6589


B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service, Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW11-0805
ALPHABETICAL INDEX

ADVANCED CONTROL SYSTEM (ACS) ............... 60-01 FAN GEARBOX .......................................................10-01


AIR CLEANER ........................................................ 70-01 FLYWHEEL AND HOUSING ...................................70-01
AIR CLEANER SERVICE ....................................... 10-01 FLYWHEEL RPM SENSOR ....................................60-01
AIR CONDITIONING SERVICE.............................. 80-01 FRONT AUXILIARY HYD. COUPLER BLOCK .......20-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 FUEL SYSTEM........................................................10-01
ALTERNATOR ........................................................ 60-01 FUEL TANK .............................................................50-01

BASIC TROUBLESHOOTING ................................ 80-01 GENERAL AIR CONDITIONING SERVICE


BATTERY................................................................ 60-01 GUIDELINES ........................................................80-01
BICS™ SYSTEM .................................................... 60-01
BOB-TACH.................................................... 10-01,50-01 HEATER COIL .........................................................80-01
BOBCAT CONTROLLER ........................................ 60-01 HEATER VALVE ......................................................80-01
BRAKE .................................................................... 40-01 HEATER/AC FAN ....................................................80-01
BUCKET POSITION VALVE ................................... 20-01 HIGH FLOW VALVE ................................................20-01
HYDRAULIC CONNECTION
CHARGE PRESSURE ............................................ 30-01 SPECIFICATIONS .......................................... SPEC-01
COMPONENTS ...................................................... 80-01 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
COMPRESSOR ...................................................... 80-01 (FOOT CONTROL)................................................20-01
CONDENSER ......................................................... 80-01 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
CONTROL HANDLE ............................................... 50-01 (ADVANCED CONTROL SYSTEM) (ACS) ...........20-01
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(ACS) SELECTABLE HAND/FOOT CONTROL.... 50-01 (FOOT CONTROL)................................................20-01
CONTROL PANEL (ADJUSTABLE PINTLES)........ 50-01 HYDRAULIC CONTROL VALVE (FOOT) ................20-01
CONTROL PANEL HYDRAULIC FILTER HOUSING ............................ 20-01
(NON-ADJUSTABLE PINTLES)............................ 50-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
CONTROL PEDALS ............................................... 50-01 HYDRAULIC PUMP ................................................20-01
CONTROL PEDALS (ACS) .................................... 50-01 HYDRAULIC PUMP (HI FLOW) ..............................20-01
CONVERSIONS ................................................SPEC-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
COOLING FAN ....................................................... 70-01 HYDRAULIC/HYDROSTATIC FLUID
CYLINDER (LIFT) ................................................... 20-01 SPECIFICATIONS ............................................. SPEC-01
CYLINDER (POWER BOB-TACH).......................... 20-01 HYDRAULIC/HYDROSTATIC SYSTEM..................10-01
CYLINDER (TILT) ................................................... 20-01 HYDROSTATIC MOTOR .........................................30-01
HYDROSTATIC PUMP ............................................30-01
DIAGNOSTICS ....................................................... 60-01 HYDROSTATIC SYSTEM INFORMATION..............30-01
DRIVE BELT ........................................................... 30-01
DRIVE COMPONENTS .......................................... 40-01 INSTRUMENT PANEL.............................................60-01

ELECTRICAL SYSTEM INFORMATION ................ 60-01 LIFT ARM ................................................................50-01


ELECTRICAL/HYDRAULIC CONTROLS LIFT ARM BY-PASS CONTROL VALVE..................20-01
REFERENCE ....................................................... 60-01 LIFT ARM SUPPORT DEVICE................................10-01
ENGINE .................................................................. 70-01 LIFTING AND BLOCKING THE LOADER...............10-01
ENGINE COMPONENTS AND TESTING .............. 70-01 LIGHTS....................................................................60-01
ENGINE COOLING SYSTEM ................................. 10-01 LOADER SPECIFICATIONS ............................. SPEC-01
ENGINE LUBRICATION SYSTEM.......................... 10-01 LUBRICATION OF THE BOBCAT LOADER ...........10-01
ENGINE SPECIFICATIONS-
KUBOTA V2003-M-DI-T..................................SPEC-01 MAIN RELIEF VALVE ..............................................20-01
ENGINE SPECIFICATIONS- MUFFLER................................................................70-01
KUBOTA V2403-M-DI-T..................................SPEC-01
ENGINE SPEED CONTROL .................................. 70-01 OIL COOLER...........................................................30-01
EVAPORATOR........................................................ 80-01 OPERATOR CAB ..........................................10-01,50-01
EVAPORATOR/HEATER UNIT ............................... 80-01 OPERATOR SEAT (SUSPENSION)........................50-01
EXPANSION VALVE ............................................... 80-01
ALPHABETICAL INDEX

POWER BOB-TACH ................................................50-01


POWER BOB-TACH (OPTION)...............................10-01
POWER BOB-TACH BLOCK...................................20-01
PRESSURE RELIEF VALVE ...................................80-01
PRESSURE SWITCH..............................................80-01

RADIATOR...............................................................70-01
REAR AUXILIARY DIVERTER VALVE ....................20-01
REAR DOOR ...........................................................50-01
REAR GRILL ...........................................................50-01
RECEIVER/DRIER ..................................................80-01
RECONDITIONING THE ENGINE ..........................70-01
REGULAR MAINTENANCE ....................................80-01
REMOTE START .....................................................10-01

SAFETY...................................................................80-01
SEAT BAR ...............................................................50-01
SEAT BAR SENSOR ...............................................60-01
SELECT VALVE.......................................................20-01
SERVICE SCHEDULE ............................................10-01
SPARK ARRESTOR MUFFLER ..............................10-01
STARTER ................................................................60-01
SYSTEM CHARGING AND RECLAMATION ..........80-01
SYSTEM TROUBLESHOOTING CHART ...............80-01

TEMPERATURE/PRESSURE .................................80-01
THERMOSTAT.........................................................80-01
TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE BOBCAT LOADER.............10-01
TROUBLESHOOTING.............................................70-01
TURBOCHARGER ..................................................70-01

ACS-ADVANCED CONTROL SYSTEM


BICS-BOBCAT INTERLOCK CONTROL SYSTEM
SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC


SYSTEM
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .IX

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .X HYDROSTATIC


SYSTEM
BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI

SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE


SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01


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

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL


SYSTEM &
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01 ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
ENGINE
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01 SERVICE

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01

HVAC

SPECIFICATIONS

SPECIFICATIONS

T190 Bobcat Loader


i Service Manual
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.

2. Check that ROPS mounting 10. Enclosure door latches must


hardware is tightened and is open and close freely.
Bobcat approved.

3. The seat belt must be 11. Bob-Tach wedges and


correctly installed, functional linkages must function
and in good condition. correctly and be in good
condition.

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


correctly adjusted, clean and condition.
lubricated.

5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).

6. Machine signs must be 14. Check hydraulic fluid level,


legible and in the correct engine oil level and fuel
location. supply.

7. Steering levers and foot 15. Inspect for fuel, oil or


pedals must return to neutral. hydraulic fluid leaks.

8. Check for correct function of 16. Lubricate the loader.


the work lights

T190 Bobcat Loader


ii Service Manual
17. Check the condition of the 22. Operate the loader and check
battery and cables. all functions.

18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.

19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tracks for wear and 25. Recommend to the owner
tension. that all necessary corrections
be made before the machine
is returned to service.

21. Inspect for loose or broken


parts or connections.

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

T190 Bobcat Loader


iii Service Manual
SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903 operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.

• The Skid-Steer Loader Operator Training Course is


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

• The Skid-Steer Loader Safety Video is available from


your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.

SI SSL-0206 SM

T190 Bobcat Loader


V Service Manual
SAFETY INSTRUCTIONS (CONT’D)

The dealer and owner/operator review the recommended


uses of the product when delivered. If the owner/operator
will be using the machine for a different application(s) he
or she must ask the dealer for recommendations on the
new use.

Call Before You Dig


1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)

SI SSL-0206 SM

T190 Bobcat Loader


VI Service Manual
SAFETY INSTRUCTIONS (CONT’D) • Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.

The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.

Flammable debris (leaves, straw, etc.) must be removed


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

The spark arrestor muffler is designed to control the


emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.

• Do not use the machine where exhaust, arcs, sparks


or hot components can contact flammable material,
explosive dust or gases.

• The operator cab, engine compartment, and engine


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

• Check all electrical wiring and connections for


damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for


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

• Do not use ether or starting fluids on any engine


which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.

• Always clean the machine, disconnect the battery,


and disconnect the wiring from the controllers before
welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the
machine when welding. Have good ventilation when
grinding or welding painted parts. Wear a dust mask
when grinding painted parts. Toxic dust or gas can be
produced.

• Stop the engine and let it cool before adding fuel. NO


SMOKING!
SI SSL-0206 SM

T190 Bobcat Loader


VII Service Manual
SERIAL NUMBER LOCATIONS Engine Serial Number

Always use the serial number of the loader when Figure 3


requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.

Loader Serial Number

Figure 2

P-48002

The engine serial number is in the location shown


[Figure 3].

P-45263

The loader serial number plate is located on the outside


of the loader frame [Figure 2].

Explanation of loader Serial Number:

XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)

1. The four digit Model/Engine Combination Module


number identifies the model number and engine
combination.

2. The five digit Production Sequence Number identifies


the order which the loader is produced.

T190 Bobcat Loader


IX Service Manual
DELIVERY REPORT

Figure 4

B-16315

The Delivery Report must be filled out by the dealer and


signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure
4].

T190 Bobcat Loader


X Service Manual
BOBCAT LOADER IDENTIFICATION

FRONT LIGHTS

SEAT BAR

GRAB OPERATOR SEAT


HANDLES WITH SEAT BELT

STEERING
LEVER
▼ REAR AUXILIARY
QUICK COUPLERS
TILT CYLINDER

† BUCKET STABILIZER ROD

FRONT AUXILIARY
QUICK COUPLERS

BUCKET STEPS
SAFETY TREAD

● OPERATOR CAB
REAR WINDOW (ROPS & FOPS)
LIFT ARM LINK

REAR GRILL
LIFT ARM

LIFT CYLINDER
TAIL LIGHT

LIFT ARM
SUPPORT DEVICE

REAR LIGHT

REAR DOOR

❒ TRACKS
B-15984
B-15985

▼ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)


❒ TRACKS - Optional tracks are available.
† Bucket - Several different buckets and other attachments are available for this machine.
● ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure
per ISO 3449, Level I. Level II is available. Extra insulated cab is available as an option (Reduced noise level).

T190 Bobcat Loader


XI Service Manual
SAFETY &
SAFETY & MAINTENANCE MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-140-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1


Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Replacing the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
DRIVE
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1 SYSTEM
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2

FAN GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1


Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
ELECTRICAL
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 SYSTEM &
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ANALYSIS
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-2 ENGINE
SERVICE
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . 10-120-1

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1


Installing Lift Arm Support Device . . . . . . . . . . . . . . . . . . . 10-20-1
Removing Lift Arm Support Device . . . . . . . . . . . . . . . . . . 10-20-2

LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Single Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-2

LUBRICATION OF THE BOBCAT LOADER. . . . . . . . . . . . . 10-150-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Continued On Next Page

T190 Bobcat Loader


10-01 Service Manual
SAFETY & MAINTENANCE (CONT’D)

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

POWER BOB-TACH (OPTION) . . . . . . . . . . . . . . . . . . . . . . 10-141-1


Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-141-1

REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1


Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-160-1


Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

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


Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE SEE STANDARD


TORQUE SPECIFICATIONS FOR BOLTS, SPEC SECTION UNLESS OTHERWISE
SPECIFIED.

T190 Bobcat Loader


10-02 Service Manual
LIFTING AND BLOCKING THE LOADER Figure 10-10-2

WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0903 P-24491

Figure 10-10-1 Always park the loader on a level surface.

Put floor jack under the rear of the loader [Figure 10-10-
2].

Lift the rear of the loader and install jackstands [Figure


10-10-2].

Figure 10-10-3

B-7023A

Procedure

WARNING P-24646

Put jackstands under the front axles and rear corners


of the frame before running the engine for service.
Put the floor jack under the front of the loader [Figure 10-
Failure to use jackstands can allow the machine to
10-3].
fall or move and cause injury or death.
W-2017-0286
Lift the front of the loader and put jackstands under the
axle tubes [Figure 10-10-3].

NOTE: Make sure the jackstands do not touch the


tracks. Make sure the tracks clear the floor or
any obstacles.

T190 Bobcat Loader


10-10-1 Service Manual
LIFTING AND BLOCKING THE LOADER (CONT’D)

Single Point Lift

Figure 10-10-4

TS-1998

The loader can be lifted with the Single Point Lift which is
available as a kit from your Bobcat loader dealer.

Install the kit as explained in the Instructions with the kit


and attach lift as shown [Figure 10-10-4].

The Single Point Lift, supplied by Bobcat, is designed to


lift and support the Bobcat loader without affecting roll
over and falling object protection features of the operator
cab.

T190 Bobcat Loader


10-10-2 Service Manual
LIFT ARM SUPPORT DEVICE

Installing Lift Arm Support Device

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Figure 10-20-2
to fall and cause injury or death.
W-2059-0598

WARNING
N-18483
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2271-1197

Figure 10-20-1 P-24484

The operator must be in the operator's seat, with the seat


1 belt fastened and seat bar lowered, until the lift arm
support device is installed.

P-24483
Start the engine, and raise the lift arms all the way up.

Have a second person install the lift arm support device


(Item 1) [Figure 10-20-2] over the rod of one of the lift
cylinders.

The lift arm support device must be tight against the


cylinder rod. The tabs of the lift arm support device must
P-24483 be under the cylinder as shown (Inset) [Figure 10-20-2].

Put jackstands under the rear corners of the loader frame


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

Remove the lift arm support device (Item 1) [Figure 10-


20-1] from storage position.

T190 Bobcat Loader


10-20-1 Service Manual
LIFT ARM SUPPORT DEVICE (CONT’D)

Installing Lift Arm Support Device (Cont’d)

Figure 10-20-3

P-24486

Lower the lift arms slowly until the lift arm support device
(Item 1) [Figure 10-20-3] is held between the lift arms
and lift cylinder.

Removing Lift Arm Support Device

The operator must be in the operator's seat, with the seat


belt fastened and seat bar lowered, until the lift arm
support device is removed and the lift arms are lowered
all the way.

Start the engine, raise the lift arms all the way up.

Have a second person remove the lift arm support


device.

Lower the lift arms all the way and stop the engine.

Return the lift arm support device to storage position and


secure with clamping knobs.

Remove the jackstands.

T190 Bobcat Loader


10-20-2 Service Manual
OPERATOR CAB Figure 10-30-1

Description

The Bobcat loader has an operator cab (ROPS and


FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for roll over protection.

ROPS/FOPS - Roll Over Protective Structure per SAE


J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449, Level I. Level II
is available.

Level I - Protection from falling bricks, small concrete


blocks, and hand tools encountered in operations such
as highway maintenance, landscaping, and other
construction site services. Always stop the engine before raising or lowering the
cab.
Level II - Protection from falling trees, rocks; for
machines involved in site clearing, overhead demolition Stop the loader on a level surface. Lower the lift arms. If
or forestry. the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Installing Lift Arm
Raising The Operator Cab Support Device on Page 10-20-1.)

Install jackstands under the rear of the loader frame


[Figure 10-30-1].

Figure 10-30-2

WARNING P10564 P10563

Never modify operator cab by welding, grinding, Loosen the nut (both sides) at the front corners of the
drilling holes or adding attachments unless operator cab [Figure 10-30-2].
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover Remove the nuts and plates [Figure 10-30-2] (both
and falling objects, and result in injury or death. sides).
W-2069-1299

T190 Bobcat Loader


10-30-1 Service Manual
OPERATOR CAB (CONT'D)

Raising The Operator Cab (Cont’d)

Figure 10-30-3

Figure 10-30-5

P-24481

Lift on the grab handle and bottom of the operator cab


slowly until the cab is all the way up and the latching
mechanism engages [Figure 10-30-3].

Lowering The Operator Cab

P10564 P10563
Figure 10-30-4

Install the plates and nuts [Figure 10-30-5] (both sides).

Tighten the nuts to 40-50 ft.-lbs. (54-68 Nm) torque.

P-24482

P-24482

Always stop the engine before raising or lowering the


cab.

NOTE: Make sure the seat bar is fully raised or


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

Release the latching mechanism (Inset) [Figure 10-30-4]


and pull the cab all the way down.

Pull down on the bottom of the operator cab until it stops


at the latching mechanism [Figure 10-30-4].

T190 Bobcat Loader


10-30-2 Service Manual
OPERATOR CAB (CONT'D) Figure 10-30-8

Emergency Exit

Figure 10-30-6

N-20171

Front Door (If Equipped)


N-19385
NOTE: When an Operator Cab Enclosure Kit is
installed, the window of the front door can be
The front opening on the operator cab and rear window used as an emergency exit. [Figure 10-30-8]
provide exits.
NOTE: If the loader has a Special Application Door
Pull on the tag on the top of the rear window to remove Kit installed, the window of the front door is
the rubber cord [Figure 10-30-6]. NOT an emergency exit.

Figure 10-30-7 Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-30-8].

Figure 10-30-9

X
N-18495

Push the rear window out of the rear of the operator cab.
P-24472

Exit through the rear of the operator cab [Figure 10-30-


7]. Push the window out with your foot [Figure 10-30-9] at
any corner of the window.

Exit through the front door.

T190 Bobcat Loader


10-30-3 Service Manual
TRANSPORTING THE BOBCAT LOADER Figure 10-40-2

Procedure

WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when P-24480 P-24785
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0494

Figure 10-40-1

6718401

P-24513
1

P-24512
Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
Be sure the transport and towing vehicles are of during sudden stops or when going up or down slopes
adequate size and capacity. (See LOADER [Figure 10-40-2].
SPECIFICATIONS on Page SPEC-10-1.).
• Lower the bucket or attachment to the floor.
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 10- • Stop the engine.
40-1].
• Engage the parking brake.
The rear of the trailer must be blocked or supported (Item
1) [Figure 10-40-1] when loading or unloading the loader • Install chains at the front and rear loader tie down
to prevent the front end of the trailer from raising up. positions (Insets) [Figure 10-40-2].

• Fasten each end of the chain to the transport vehicle.

T190 Bobcat Loader


10-40-1 Service Manual
TOWING THE LOADER

Procedure

Because of the design of the loader, there is not a


recommended towing procedure.

• The loader can be lifted onto a transport vehicle.

• The loader can be skidded a short distance to move


for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tires/tracks will not turn.) There might be slight
wear to the tires/tracks when the loader is skidded.

The towing chain (or cable) must be rated at 1 & 1/2


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

T190 Bobcat Loader


10-50-1 Service Manual
REMOTE START Figure 10-60-2

Procedure

WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
1
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
P-24651
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899
Figure 10-60-3

Figure 10-60-1

1
1

P-24653

P16115
Lift and block the loader. (See Procedure on Page 10-10-
1.)
The tool listed will be need to do the following procedure:
Raise the lift arms (if required by the procedure) and
MEL1563 - Remote Start Tool Kit install an approved lift arm support device. (See Installing
Lift Arm Support Device on Page 10-20-1.)
The remote start (Item 1) [Figure 10-60-1] is required
when the operator cab is in the raised position for service Raise the operator cab (if required by the procedure).
and the service technician needs to turn the key switch (See Raising The Operator Cab on Page 10-30-1.)
on or start the engine. Example: Control Handle: linkage
neutral adjustment. Open the rear door of the loader.

Remove the plug (Item 1) [Figure 10-60-2] or disconnect


the attachment control harness (Item 1) [Figure 10-60-3]
if connected.

T190 Bobcat Loader


10-60-1 Service Manual
REMOTE START (CONT'D)

Procedure (Cont'd)

Figure 10-60-4

1 Figure 10-60-6

P-24652

Connect the remote start tool to the engine harness


connector (Item 1) [Figure 10-60-4].

NOTE: The key switch on the right-hand side 2


3 1
operator panel must be in the off position or
the Remote Start Kit will not operate.

Figure 10-60-5
P16118

The traction lock switch (Item 1) [Figure 10-60-6] is used


to turn traction lock on or off. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
1 able to turn.

The maximum flow/variable flow switch (Item 2) [Figure


10-60-6] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to indicate which flow rate is
active. Pressing the switch a third time will turn the flow
P16116 OFF. The switch is used when checking pressures and
flow rate.
The remote start tool (Item 1) [Figure 10-60-5] has three The auxiliary pressure release (Item 3) [Figure 10-60-6]
rocker switches. is used to release hydraulic pressure to the rear auxiliary
couplers. To release pressure; push and hold the switch
for three seconds.

NOTE: With the engine running; pushing and holding


the pressure release switch will cause the
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.

T190 Bobcat Loader


10-60-2 Service Manual
REMOTE START (CONT'D)

Procedure (Cont'd)

Figure 10-60-7

P-34661

Push the couplers on the front auxiliary block toward the


block and hold for five seconds to release the front
auxiliary pressure [Figure 10-60-7].

T190 Bobcat Loader


10-60-3 Service Manual
SERVICE SCHEDULE

Chart

Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader

Instructions are necessary before operating or servicing machine. Read and


understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0903

SERVICE SCHEDULE HOURS

■ ■ ■
ITEM SERVICE REQUIRED
8-10 50 100 250 500 1000
Engine Oil Check the oil level and add oil as needed.
Engine Air Filter and Air Check display panel. Service only when required. Check for leaks and
System damaged components.
Engine Cooling System Clean debris from oil cooler, radiator and grill. Check coolant level in recovery
tank. Add coolant as needed.
Seat Belt, Seat Bar and Check the condition of seat belt. Check the seat bar and control interlocks.
Control Interlocks Clean dirt and debris from moving parts.
Safety Signs and Safety Tread Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Indicators & Lights (Opt.) Check for correct operation of all indicators & lights.
Operator Cab Check the fastening bolts, washers & nuts. Check the condition of cab.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
Fuel Filter Remove the trapped water.
Bobcat Interlock Control Check that four BICS™ indicator lights and functions are acti- vated. See
System (BICS™) details in this Operation & Maintenance Manual.
Heater and A/C Filters Clean or replace filters as needed during heating/cooling season.
Tracks Check for damaged or worn tracks and correct tension. ‡
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Foot Pedals or Hand Controls, Check for correct operation. Repair or adjust as needed.
and Steering Levers
Parking Brake Check operation.
Track Sprocket Bolts Check torque. Tighten as needed. See procedure in this manual. ◆
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Shaft Grease two fittings.
Engine/Hydros. Drive Belt Check for wear or damage. Adjust as needed.
Fan Drive Gearbox Check gear lube level. Add as needed.
Alternator Belt & Air Check belt tension and adjust as needed.
Conditioner Belt (If Equipped)
Engine Oil and Filter Replace oil and filter. Use CD or better grade oil and Bobcat filter. †
Fuel Filter Replace the filter element.
Bobcat Interlock Control Check the function of the lift arm bypass control.
System (BICS™)
Hydraulic Reservoir Breather Replace the reservoir breather cap.
Cap
Hydraulic/Hydrostatic Filter Replace the filter element. •
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters. ■

Hydrostatic Motor Carrier Replace Oil with High Performance Synthetic Oil P/N 6682546.
■ Or every 12 months.
† First oil and filter change must occur at 50 hours; 250 hours thereafter.
* Inspect the new belt after first 50 hours.
• Replace filter element after the first 50 hours and when the transmission warning light comes ON.
‡ Check every 8-10 hours for the first 50 hours. Then at 50 hour intervals.
◆ Check after the first 50 hours of operation only.

T190 Bobcat Loader


10-70-1 Service Manual
AIR CLEANER SERVICE Figure 10-80-3

Replacing Filter Element

Figure 10-80-1

P-31836

Outer Filter
B-15552B
B-15553B
Remove the wing nut and remove the dust cover [Figure
10-80-3].
It is important to change the air filter element only when
the Air Cleaner Icon in the right panel is ON (Item 1) Figure 10-80-4
[Figure 10-80-1] and you hear three beeps from the
alarm.

Replace the inner filter every third time the outer filter is
replaced or as indicated.

Figure 10-80-2

1
2
P-31837

1
Remove the wing nut and remove the outer filter element
(Item 1) [Figure 10-80-4].

NOTE: Make sure all sealing surfaces are free of dirt


B-15551 and debris.

Install a new outer element.


Press and hold the LIGHT Button (Item 1) [Figure 10-80-
2] for two seconds. Install the dust cover and the wing nut [Figure 10-80-3]
(Be sure the evacuator is down).
If the filter element needs replacement, the CODE [01-
17] (Air Filter Plugged) will show in the HOURMETER / Check the air intake hose and the air cleaner housing for
CODE DISPLAY (Item 2) [Figure 10-80-2]. damage. Make sure all connections are tight.

T190 Bobcat Loader


10-80-1 Service Manual
AIR CLEANER SERVICE (CONT'D) Figure 10-80-6

Replacing Filter Element (Cont'd)

Figure 10-80-5

P-31836

Install the dust cover and the wing nut [Figure 10-80-6]
P-31838 (Be sure the evacuator is down).

Inner Filter

Only replace the inner filter element under the following


conditions:

Replace the inner filter element every third time the outer
filter is replaced.

After the outer element has been replaced, start the


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

Remove the wing nut and remove the inner filter element
[Figure 10-80-5].

Install the new inner element.

Install the outer element.

T190 Bobcat Loader


10-80-2 Service Manual
ENGINE COOLING SYSTEM

Cleaning The Cooling System


IMPORTANT
AVOID ENGINE DAMAGE
WARNING Always use the correct ratio of water to antifreeze.

To much antifreeze reduces cooling system


Wear safety glasses to prevent eye injury when any efficiency and may cause serious premature engine
of the following conditions exist: damage.
• When fluids are under pressure.
• Flying debris or loose material is present. Too little antifreeze reduces the additives which
• Engine is running. protect the internal engine components; reduces the
• Tools are being used. boiling point and freeze protection of the system.
W-2019-1285

Always add a premixed solution. Adding full strength


Figure 10-90-1 concentrated coolant can cause serious premature
engine damage.
I-2124-0497

Figure 10-90-2

P-45101

Check the cooling system every day to prevent over-


heating, loss of performance or engine damage.
P-45103

Open the rear door and remove the rear grill.(See


Removal And Installation on Page 50-60-1.) Raise the air conditioning condenser (If equipped) and
the oil cooler and clean the top of the radiator [Figure 10-
Use air pressure or water pressure to clean the top of the 90-2].
oil cooler [Figure 10-90-1].
Lower the oil cooler on the loader frame.

Check cooling system for leaks.


WARNING Replace the rear grill and close the rear door.
Do not use your bare hands to remove debris from
the oil cooler. Cooling fins are sharp and may cause
injury.
W-2460-0303

T190 Bobcat Loader


10-90-1 Service Manual
ENGINE COOLING SYSTEM (CONT'D) Replacing the Coolant

Checking The Coolant Level

Figure 10-90-3
WARNING
MAX Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1285

MIN P-45106 Figure 10-90-4

P-45102

Open the rear door and remove the rear grill.

Check the coolant level [Figure 10-90-3]. The level


markers are on the outside of the tank. Coolant must be
between the bottom marker and the top marker when the
P-45102
engine is cold.

Replace the rear grill and close the rear door before Open the rear door and remove the rear grill.
operating the loader.
Remove the radiator cap (Item 1) [Figure 10-90-4].

IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.

To much antifreeze reduces cooling system


efficiency and may cause serious premature engine
damage.

Too little antifreeze reduces the additives which


protect the internal engine components; reduces the
boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength


concentrated coolant can cause serious premature
engine damage.
I-2124-0497

T190 Bobcat Loader


10-90-2 Service Manual
ENGINE COOLING SYSTEM (CONT'D)

Replacing the Coolant (Cont’d)

Figure 10-90-5

P-48075

Turn the valve (Item 1) [Figure 10-90-5] 90 degrees


and drain the coolant into a container.

Recycle or dispose of used coolant in an environmentally


safe manner. Close the drain valve and remove the hose.

NOTE: The loader is factory filled with propylene


glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.

Add premixed coolant, 47% water and 53% propylene


glycol to the recovery tank if the coolant level is low.

One gallon and one pint (4,3 L) of propylene glycol mixed


with one gallon (3,8 L) of water is the correct mixture of
coolant to provide a -34°F (-37°C) freeze protection.

Use a refractometer to check the condition of propylene


glycol in your cooling system.

Fill the radiator with the premixed coolant. Install the


radiator cap.

Remove the cover from the coolant recovery tank. Fill the
tank until it is at the lower marker (inside the tank).

Run the engine until it is at operating temperature.

Stop the engine.

Check the coolant level in the recovery tank when cool.

Add coolant as needed.

Replace the rear grill and close the rear door.

T190 Bobcat Loader


10-90-3 Service Manual
FUEL SYSTEM Filling The Fuel Tank

Fuel Specifications

Figure 10-100-1
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0887

1
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
P-48074
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. Open the rear door.

The following is one suggested blending guideline which Remove the fuel fill cap (Item 1) [Figure 10-100-1].
should prevent fuel gelling during cold temperatures:
Figure 10-100-2
Temp. F° (C°) No. 2 No. 1
WRONG
+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%

Contact your fuel supplier for local recommendations.

B-15650A

Use a clean, approved safety container to add fuel of the


correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].

Install and tighten the fuel fill cap (Item 1) [Figure 10-
100-1].

T190 Bobcat Loader


10-100-1 Service Manual
FUEL SYSTEM (CONT’D) W-2072-0496

Fuel Filter
Figure 10-100-4
Figure 10-100-3

2
1
1 2

P-48076

P-48077

Open the vent (Item 1) [Figure 10-100-4] on the fuel filter


housing.
(See SERVICE SCHEDULE on Page 10-70-1), for the
service interval for removing water from, or replacing the Squeeze the hand pump (priming bulb) (Item 2) [Figure
fuel filter. 10-100-4] until fuel flows from the vent with no air
bubbles.
Removing Water
Close the vent (Item 1) [Figure 10-100-4] on the fuel
Loosen the drain (Item 1) [Figure 10-100-3] at the filter housing.
bottom of the filter element to remove water from the
filter. Open the vent (Item 3) [Figure 10-100-4] on the fuel
injection pump.
Replacing Element
Squeeze the hand pump (priming bulb) (Item 2) [Figure
Remove the filter element (Item 2) [Figure 10-100-3]. 10-100-4] until the pump feels solid.
Clean the area around the filter housing. Put clean oil on Tighten the vent plug (Item 3) [Figure 10-100-4].
the seal of the new filter element. Install the fuel filter, and
hand tighten. Start the engine.

Remove the air from the fuel system. (See Removing Air It may be necessary to open the vent plug (Item 3)
From The Fuel System on Page 10-100-2) [Figure 10-100-4] briefly while the engine is running.
Close the vent when the engine runs smoothly.
Removing Air From The Fuel System

After replacing the filter element or when the fuel tank


has run out of fuel, the air must be removed from the fuel
system before starting the engine.

WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.

T190 Bobcat Loader


10-100-2 Service Manual
ENGINE LUBRICATION SYSTEM Oil Chart

Checking Engine Oil

Check the engine oil level every day before starting the
engine for the work shift.

Figure 10-110-1

P-48079

Park the loader on level ground.

Open the rear door and remove the dipstick (Item 1)


[Figure 10-110-1].

Keep the oil level between the marks on the dipstick. DO


NOT OVERFILL.

Use a good quality motor oil that meets API Service


Classification of CD or better. (See Oil Chart.)

Install the dipstick and close the rear door.

T190 Bobcat Loader


10-110-1 Service Manual
ENGINE LUBRICATION SYSTEM (CONT’D)

Replacing Oil And Filter


WARNING
(See SERVICE SCHEDULE on Page 10-70-1), for the
service interval for replacing the engine oil and filter. Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Run the engine until it is at operating temperature. Park Failure to use care around combustibles can cause
the loader on level ground and stop the engine. explosion or fire which can result in injury or death.
W-2103-1285

Open the rear door.


Figure 10-110-3
Figure 10-110-2

1
3

1 P-1575
P-48078

Put oil in the engine. (See Capacities on Page SPEC-10-


Remove the drain plug (Item 1) [Figure 10-110-2]. 4.) [Figure 10-110-3] (See Oil Chart on Page 10-110-1.)

Drain the oil into a container and dispose of used oil in an Start the engine and let it run for several minutes.
environmentally safe manner.
Stop the engine and check for leaks at the oil filter.
Remove the oil filter (Item 2) [Figure 10-110-2].
Remove the dipstick and check the oil level.
Clean the filter housing surface.
Add oil until it reaches the top mark (Item 1) [Figure 10-
Put clean oil on the new oil filter gasket. 110-3] on the dipstick. DO NOT OVERFILL.

Install the filter and hand tighten. Install the dipstick and the fill plug.

Install and tighten the drain plug. Close the rear door.

Remove the fill cap (Item 3) [Figure 10-110-2].

T190 Bobcat Loader


10-110-2 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM Replacing Hydraulic/Hydrostatic Filter

Checking And Adding Fluid (See SERVICE SCHEDULE on Page 10-70-1), for the
correct service intervals.
Figure 10-120-1
Open the rear door.

Figure 10-120-3

1
P-24478A P-24478

Use only recommended fluid in the hydraulic system.


P-45244
(See HYDRAULIC/HYDROSTATIC FLUID
SPECIFICATIONS on Page SPEC-60-1.)
Remove the filter element (Item 1) [Figure 10-120-3]
Stop the loader on a level surface,
Clean the surface of the filter housing where the seal
Lower the lift arms and tilt the Bob-Tach fully back. contacts the housing.

Stop the engine. Put clean oil on the seal of the new filter element.

Install and hand tighten the filter element.


Check the fluid level in the sight gauge [Figure 10-120-1]
on the left side of the loader, above the track.
Close the rear door before operating the loader.
Figure 10-120-2

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
1 physician familiar with this injury is not received
immediately.
W-2145-0290

P-45245
WARNING
Open the rear door and remove the rear grill. Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Remove the fill cap (Item 1) [Figure 10-120-2] Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
Add the fluid as needed to bring the level to the center of W-2103-1285
the sight gauge [Figure 10-120-1]and install the fill cap.

T190 Bobcat Loader


10-120-1 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Figure 10-120-5

Replacing Hydraulic Fluid


1
Figure 10-120-4

P-24751

Raise the operator cab. (See Raising The Operator Cab


P-45245 on Page 10-30-1.)

Remove plug (Item 1) [Figure 10-120-5] from hydraulic


((See SERVICE SCHEDULE on Page 10-70-1), for the reservoir and pump the hydraulic fluid into a container.
service interval.
Figure 10-120-6
The fluid must be replaced if it becomes contaminated or
after major repairs. If the fluid is replaced, the hydrostatic RIGHT CASE
DRAIN FILTER
filter and both case drain filters must be replaced.

Remove the rear grill. [Figure 10-120-4]

Remove the reservoir fill cap (Item 1) [Figure 10-120-4] 2

P-24683 P-48429

Disconnect the hoses (Item 1) [Figure 10-120-6] from


the case drain filter located under the control valve. Cap
and plug the hoses and case drain filter to prevent
leakage.

T190 Bobcat Loader


10-120-2 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Figure 10-120-8

Replacing Hydraulic Fluid (Cont’d)

Figure 10-120-7

LEFT CASE
DRAIN FILTER 2
1

P-64316

The hydrostatic charge pressure filter shown [Figure 10-


P-24734 120-8] is located behind the control panel and in front of
the fuel tank.

Disconnect the hose (Item 1) [Figure 10-120-7] from the Remove and replace the hydrostatic charge pressure
case drain filter located on the reservoir. Cap and plug filter (Item 1) [Figure 10-120-8].
the hose and case drain filter to prevent leakage.

Remove the case drain filters (Item 2) [Figure 10-120-6]


& [Figure 10-120-7] and drain the fluid into a container.

Replace the hydraulic/hydrostatic filter. (See Replacing


Hydraulic/Hydrostatic Filter on Page 10-120-1.)

Replace both hydrostatic motor case drain filters (Item 2)


[Figure 10-120-6] & [Figure 10-120-7].

When the fluid is removed from the reservoir, reconnect


the hose to case drain filters.

Add the correct fluid to the reservoir until the fluid level is
at the center of the sight gauge (Do not overfill) with lift
arms lowered.

Lower the operator cab. (See Lowering The Operator


Cab on Page 10-30-2.)

Start the engine and operate the loader hydraulic


controls. Stop the engine and check for leaks.

Check the fluid level in the reservoir and add as needed.

T190 Bobcat Loader


10-120-3 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D)

Breather Cap

Figure 10-120-9

P-24687

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


correct service replacement interval.

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Remove the breather cap (Item 1) and discard.[Figure


10-120-9]

Install new cap.

Lower the operator cab. (See Lowering The Operator


Cab on Page 10-30-2.)

T190 Bobcat Loader


10-120-4 Service Manual
FAN GEARBOX

Checking And Maintaining

Figure 10-130-1

P-24688

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


correct service interval.

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Remove the plug (Item 1) [Figure 10-130-1] to check the


lubricant level.

If the level is low, add SAE 90W gear lubricant through


the check plug hole until lubricant flows from the hole.

Install and tighten the plug.

Lower the operator cab. (See Lowering The Operator


Cab on Page 10-30-2.)

T190 Bobcat Loader


10-130-1 Service Manual
BOB-TACH Figure 10-140-3

Inspection And Maintenance


Bob-Tach
Wedge

WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588 Wedge Must Contact
Lower Edge Of Hole
In the Attachment
Figure 10-140-1 B-15177

The spring loaded wedge (Item 1) [Figure 10-140-1]


must contact the lower edge of the hole in the attachment
(Item 1) [Figure 10-140-2] and [Figure 10-140-3].
1
If the wedge does not contact the lower edge of the hole
[Figure 10-140-2] and [Figure 10-140-3], the
attachment will be loose and can come off the Bob-Tach.

Figure 10-140-4

P-24695

Move the Bob-Tach levers to engage the wedges [Figure


10-140-1]. The levers and wedges must move freely.

The wedges must extend through the holes in the


attachment mounting frame (Item 1) [Figure 10-140-1].

Figure 10-140-2

B-17460

Inspect the mounting frame on the attachment and the


Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-140-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
1
Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.

Lubricate the wedges. (See LUBRICATION OF THE


BOBCAT LOADER on Page 10-150-1.)
P-24696

T190 Bobcat Loader


10-140-1 Service Manual
POWER BOB-TACH (OPTION) Figure 10-141-3

Inspection And Maintenance

Figure 10-141-1

Front Accessory Panel


1
B-15177

Wedge Must Contact Lower Edge


Of Hole In The Attachment P-24487

If the wedge does not contact the lower edge of the hole
B-15891 [Figure 10-141-3], the attachment will be loose and can
come off the Bob-Tach.

Push and hold the BOB-TACH "WEDGES UP" switch Figure 10-141-4
[Figure 10-141-1] until wedges are fully raised. Push and
hold the BOB-TACH "WEDGES DOWN" switch [Figure
10-141-1] until the wedges are fully down. The wedges
must move freely.

Figure 10-141-2

B-17460

Inspect the mounting frame on the attachment and the


1 Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-141-4]. Replace any parts including
P-24487 decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses and fittings for
leaks.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-141-2] Look for cracked welds. Contact your Bobcat dealer for
and must contact the lower edge of the hole in the repair or replacement parts.
attachment [Figure 10-141-2] and (Item 1) [Figure 10-
141-3]. Lubricate the wedges. (See LUBRICATION OF THE
BOBCAT LOADER on Page 10-150-1.)

T190 Bobcat Loader


10-141-1 Service Manual
LUBRICATION OF THE BOBCAT LOADER Figure 10-150-2

Procedure 3

Figure 10-150-1

4
Access
N-18506
Hole
P-24697

Lubricate the loader as specified in the Service


Schedule. (See SERVICE SCHEDULE on Page 10-70- Access
1), for the best performance of the loader. Hole

Record the operating hours each time you lubricate the


Bobcat loader.
P-24698
Always use a good quality lithium based multi-purpose
grease when you lubricate the loader. Apply lubricant
until extra grease shows. 2. Stabilizer Rod - Rear (Both Sides) [Figure 10-150-2].

Lubricate the following locations on the loader: 3. Lift Cylinder Rod End (Both Sides) [Figure 10-150-2]

1. Stabilizer Rod - Front (Both Sides) [Figure 10-150-1]. 4. Lift Cylinder Base End (Both Sides) [Figure 10-150-
2].

T190 Bobcat Loader


10-150-1 Service Manual
LUBRICATION OF THE BOBCAT LOADER (CONT'D) Figure 10-150-5

Procedure (Cont’d)
8
Figure 10-150-3

P-24699

9 P16045

8. Bob-Tach Wedge (Both Sides) [Figure 10-150-5].


N-18510
9. Power Bob-Tach Cylinder (Both Sides) [Figure 10-
150-5].
5. Tilt Cylinder Base End (Both Sides) [Figure 10-150-
3]. Figure 10-150-6

Figure 10-150-4

10

7
6

P-24700

P-48104
10. Lift Arm Pivot Pin (Both Sides) [Figure 10-150-6].

6. Tilt Cylinder Rod End (Both Sides) [Figure 10-150-4].

7. Bob-Tach Pivot Pin (Both Sides) [Figure 10-150-4].

T190 Bobcat Loader


10-150-2 Service Manual
LUBRICATION OF THE BOBCAT LOADER (CONT'D) PIVOT PINS

Procedure (Cont’d) Figure 10-150-9

Figure 10-150-7 1
1

P-24702A
11

P-24702

P-24701
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
11. Lift Arm Link Pivot Pin (Both Sides) [Figure 10-150- 10-150-9].
7].
Check that the lock nuts are tightened to 18-20 ft.-lbs.
Figure 10-150-8 (24-27 Nm) torque.

12

P-24703

12. 250 Hours: Steering Lever Shaft (2) [Figure 10-150-


8].

T190 Bobcat Loader


10-150-3 Service Manual
SPARK ARRESTOR MUFFLER

Cleaning Procedure
WARNING
(See SERVICE SCHEDULE on Page 10-70-1), for
service interval for cleaning the spark arrestor muffler. When the engine is running during service, the
steering levers must be in neutral and the parking
Do not operate the loader with a defective exhaust brake engaged. Failure to do so can cause injury or
system. death.
W-2006-0284

Start the engine and run for about ten seconds while a
IMPORTANT second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler.

This loader is factory equipped with a U.S.D.A. This will force contaminants out through the cleanout
Forestry Service approved spark arrestor muffler. It hole.
is necessary to do maintenance on this spark
arrestor muffler to keep it in working condition. The Stop the engine.
spark arrestor muffler must be serviced by dumping
the spark chamber every 100 hours of operation. Install and tighten the plug.

If this machine is operated on flammable forest, Lower the rear grill and close the rear door.
brush or grass covered land, it must be equipped
with a spark arrestor attached to the exhaust system
and maintained in working order. Failure to do so will
be in violation of California State Law, Section 4442
PRC. WARNING
Make reference to local laws and regulations for When an engine is running in an enclosed area, fresh
spark arrestor requirements. air must be added to avoid concentration of exhaust
I-2022-0595 fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
Figure 10-160-1 gases which can kill without warning.
W-2050-1285

WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
1 Failure to obey can cause serious injury.
W-2011-1285

P-45498 WARNING
Stop the engine. Open the rear door and rear grill. Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
Remove the plug (Item 1) [Figure 10-160-1] from the flammable material. Failure to obey warnings can
bottom of the muffler. cause injury or death.
W-2068-1285

T190 Bobcat Loader


10-160-1 Service Manual
HYDRAULIC SYSTEM

BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1


Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-5
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-3 HYDRAULIC
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1 SYSTEM
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-2

CYLINDER (LIFT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1


Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4 DRIVE
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2 SYSTEM
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2 ELECTRICAL
SYSTEM &
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 ANALYSIS
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7
Base End Pivot Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 ENGINE
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6 SERVICE
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Rod End Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . . . . 20-21-4
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-2
SPECIFICATIONS
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . 20-130-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

HIGH FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1


Checking The High Flow Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-6
High Flow Relief Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . 20-100-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-8

Continued On Next Page

T190 Bobcat Loader


20-01 Service Manual
HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCE CONTROL SYSTEM)


(ACS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Actuator Removal And Installation (Out of Loader) . . . . . . . . . . . . . . . . . . . . . 20-43-6
Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-12
Auxiliary Solenoid Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . 20-43-24
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-23
BICS™ Valve, Check Valve Removal And Installation. . . . . . . . . . . . . . . . . . 20-43-28
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . . . . . 20-43-29
BICS™ Valve, Lift Load Check Valve Removal And Installation . . . . . . . . . . 20-43-10
BICS™ Valve, Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . 20-43-26
BICS™ Valve Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . 20-43-25
End Cap Block Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-16
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Identification Chart (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-9
Lift Spool Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-17
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . . . . . . . 20-43-11
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-29
Mount Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-10
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-15
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-14
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . . . . . 20-43-13
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . . . . . 20-43-13
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . . . . . 20-43-14
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Tilt Spool Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-21

Continued On Next Page

T190 Bobcat Loader


20-02 Service Manual
HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) . . . . 20-42-1


Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-10
Auxiliary Solenoid Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . 20-42-29
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-27
BICS™ Valve, Check Valve Removal And Installation . . . . . . . . . . . . . . . . . 20-42-33
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . . . . . 20-42-34
BICS™ Valve, Lift Load Check Valve Removal And Installation . . . . . . . . . . . 20-42-8
BICS™ Valve, Lock Valve Removal And Installation. . . . . . . . . . . . . . . . . . . 20-42-31
BICS™ Valve Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . 20-42-30
End Cap/Spool Lock Block Removal and Installation . . . . . . . . . . . . . . . . . . 20-42-15
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-7
Lift Spool and Detent Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . 20-42-16
Load Check Valve Removal And Installation (Tilt & Auxiliary). . . . . . . . . . . . . 20-42-9
Main Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-34
Mount Bracket Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-8
Plug Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-13
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-12
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . . . . . 20-42-11
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . . . . . 20-42-11
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . . . . . 20-42-12
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Rubber Boot Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-14
Tilt Spool Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-25

Continued On Next Page

T190 Bobcat Loader


20-03 Service Manual
HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL


SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-12
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16
Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-21
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
BICS™ Valve, Check Valve Removal And Installation. . . . . . . . . . . . . . . . . . 20-41-8
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation . . . . . . . . 20-41-7
BICS™ Valve Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . 20-41-9
BICS™ Valve Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-5
BICS™ Valve Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-41-10
BICS™ Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-23
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Identification Chart (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-13
Lift and Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 20-41-19
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-13
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-13
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Port-Auxiliary Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-18

Continued On Next Page

T190 Bobcat Loader


20-04 Service Manual
HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) . . . 20-40-1


Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
BICS™ Valve, Check Valve Disassembly And Assembly . . . . . . . . . . . . . . . 20-40-7
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . . . . . . 20-40-6
BICS™ Valve Lock Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . 20-40-8
BICS™ Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
BICS™ Valve Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . 20-40-9
BICS™ Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Lift And Tilt Lock Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Lift Spool and Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Main Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Port-Auxiliary Section Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26

HYDRAULIC/HYDROSTATIC FILTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . 20-70-1


Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1


Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1


Check The Output Of The Hydraulic Pump With Power Bob-Tach. . . . . . . . 20-60-3
Check The Output Of The Hydraulic Pump Without Power Bob-Tach . . . . . 20-60-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5

HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1


Check The Output Of The Hydraulic Pump (High Flow) . . . . . . . . . . . . . . . . 20-61-3
Check The Output Of The Hydraulic Pump (Standard) . . . . . . . . . . . . . . . . . 20-61-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-8
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5

Continued On Next Page

T190 Bobcat Loader


20-05 Service Manual
HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-1


Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-8
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-7
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-4
Test The Output Of The Hydraulic Auxiliary Pump . . . . . . . . . . . . . . . . . . . . 20-62-1
Test The Output Of The Hydraulic Charge Pump . . . . . . . . . . . . . . . . . . . . . 20-62-2

HYDRAULIC PUMP (HIGH FLOW) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-1


Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-9
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-8
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-6
Test The Output Of The Hydraulic Auxiliary Pump . . . . . . . . . . . . . . . . . . . . 20-63-1
Test The Output Of The Hydraulic Charge Pump . . . . . . . . . . . . . . . . . . . . . 20-63-2
Test The Output Of The Hydraulic Pump (High Flow) . . . . . . . . . . . . . . . . . . 20-63-4

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1


Tighten Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5

LIFT ARM BY-PASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-1


Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-2
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-1

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30-1


Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30-2
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30-3

POWER BOB-TACH BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-120-1


Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-120-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-120-1

REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1


Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-9

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SPEC SECTION) UNLESS OTHERWISE SPECIFIED.

T190 Bobcat Loader


20-06 Service Manual
HYDRAULIC/HYDROSTATIC SCHEMATIC
T190 (S/N 527011001 AND ABOVE)
(S/N 527911001 AND ABOVE)

(PRINTED MARCH 2005)


V-0454legend
LEGEND
1 RESERVOIR:
Capacity . . . . . . . 19.2 Qts. (18,2 L) 15 LIFT CYLINDER SPOOL - MADE TO 29 RESTRICTOR - 0.031 inch (0,8 mm) 43 RELIEF/ANTICAVITATION VALVE -
RESTRICT FLOW DURING BOOM PORT (TILT BASE END)
2 SPRING LOADED FILTER BY-PASS DOWN BUT NOT DURING BOOM UP 3500 PSI (241,3 Bar)
30 RELIEF VALVE: 3300 PSI (228 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar)
16 SOLENOID ACTIVATED DIRECTIONAL 44 PILOT ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: 31 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - HYDRAULIC
CONTROL VALVE - BICS CONTROL
36-44 PSI (2,5-3,0 Bar) POWERED BOB-TACH
Normally Closed 17 PILOTED ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 45 RESTRICTION - 0.089 inch (2,26 mm)
4 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE - TILT CONTROL
BRONZE)
18 PILOTED ACTIVATED DIRECTIONAL 46 RESTRICTION - 0.025 inch (0,6 mm)
5 RELIEF/REPLENISHING VALVE - HIGH 33 FILTER - BICS CONTROL VALVE
CONTROL VALVE - LIFT CONTROL
PRESSURE: 5000 PSI (345 Bar) (SCREEN) 47
19 PULL BUTTON ACTIVATED RELIEF VALVE - 2000 PSI (137 Bar)
6 RELIEF VALVE - CHARGE INLET:
DIRECTIONAL CONTROL VALVE - LIFT 34 CHECK VALVE - BUCKET POSITION
220-270 PSI (15,1-18,6 Bar) 48 RELIEF VALVE - 1200 PSI (83 Bar)
ARM BY-PASS VALVE
at High Engine Idle
With 140 degrees F. (60 degrees C.) Fluid 20 PILOTED ACTIVATED DIRECTIONAL 49 SOLENOID ACTIVATED DIRECTIONAL
35 RESTRICTION
CONTROL VALVE - UNLOADING CONTROL VALVE (TWO COIL)
SPOOL
7 FRONT AUXILIARY MANUAL PRESSURE 36 VARIABLE CAPACITY DISPLACEMENT 50 CHECK VALVE - With 300 PSI (20,7 Bar) Spring
BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP with 0.016 inch (0,40 mm) orifice
8 CONTROL VALVE - FLOW CONTROL
HYDRAULIC PUMP . . . . . . . Gear Type 16.9 37 SHUTTLE RELIEF VALVE 51 HYDRAULIC BRAKE - SPRING APPLIED -
SPOOL
GPM (64 L/min.) at High Engine Idle (Not Adjustable - Factory Set) PRESSURE RELEASE
22 FLOW DIVIDER ADJUSTMENT VALVE 65 PSI (4,5 Bar) 52 CHECK VALVE
9 RELIEF VALVE - MAIN:
3250-3350 PSI (224-231 Bar) 23 SOLENOID ACTIVATED DIRECTIONAL 38 FIXED CAPACITY DISPLACEMENT 53 RELIEF VALVE - BRAKE PRESSURE
at Front Quick Couplers CONTROL VALVE - BASE BIDIRECTIONAL HYDROSTATIC 500 PSI (34,5 Bar)
MOTOR
10 RELIEF VALVE - PORT: . . . . . (Optional) 24 SOLENOID ACTIVATED DIRECTIONAL 55 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (241,3 Bar) CONTROL VALVE - ROD 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring CONTROL VALVE
11 ANTICAVITATION VALVE
25 LOAD SHUTTLE VALVE - BLEED OFF 40 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
12 SOLENOID ACTIVATED DIRECTIONAL 26 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF)
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL
13 RELIEF VALVE - PORT: . . . . . (Optional) 41 CHECK VALVE - BICS CONTROL VALVE
27 PILOT ACTIVATED DIRECTIONAL
3100 PSI (213,7 Bar)
CONTROL VALVE - REAR AUXILIARY 42 RELIEF VALVE - PORT:
14 LOAD CHECK VALVE 3500 PSI (241,3 Bar)
28 RESTRICTOR - 0.140 inch (3,6 mm)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.

Printed in U.S.A. V-0454legend (3-10-05)


(REAR QUICK
FEMALE COUPLERS) MALE

HYDRAULIC/HYDROSTATIC SCHEMATIC
T190 (S/N 527011001 AND ABOVE)
BASE ROD REAR AUX VALVE (OPTIONAL)
(S/N 527911001 AND ABOVE)
(PRINTED MARCH 2005) INTEGRATED QUICK
23 24 COUPLER BLOCK
V-0454
25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
29
1 30
FEMALE
27

4 37

P-OUT P-IN T
51

32 BUCKET POSITION VALVE (OPTIONAL)

D
38 HYDRAULIC FILTER 34

31

OIL
2 22
COOLER
B HYDROSTATIC PUMPS A

5 36
5
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21

20

12 12
CHARGE 13 B
INLET B A

AUXILIARY
SPOOL
14
36
43 TILT CYLINDERS
BOB-TACH BICS CONTROL VALVE
5 5 CYLINDER
D C (OPTIONAL)
HYDRAULIC
POWERED
8 BOB-TACH
(OPTIONAL)
INLET OUTLET
BRAKE VALVE 39 47
B A 17
DR 42 TILT
T 53 52 CYLINDER
SPOOL

IN 50 11
48
DRIVE MOTOR 46 14
38 LIFT CYLINDERS
49 10
45
PP 18
54
P2 B A
P1 LIFT
44 CYLINDER
B1 A1 51
SPOOL 35
B2 A2 15

14
4 37

9 16 WORKING CIRCUITS
33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS

LIFT ARM BY PASS VALVE


32
19

Printed in U.S.A. V-0454 (3-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
T190 (S/N 527011001 AND ABOVE)
(S/N 527911001 AND ABOVE)

(PRINTED MARCH 2005)


V-0455legend
LEGEND
1 RESERVOIR:
Capacity . . . . . . . 19.2 Qt. (18,2 L) 15 LIFT CYLINDER SPOOL - MADE TO 29 RESTRICTOR - 0.031 inch (0,8 mm) 43 RELIEF/ANTICAVITATION VALVE -
RESTRICT FLOW DURING BOOM PORT (TILT BASE END)
2 SPRING LOADED FILTER BY-PASS DOWN BUT NOT DURING BOOM UP 3500 PSI (241,3 Bar)
30 RELIEF VALVE: 3300 PSI (228 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar)
16 SOLENOID ACTIVATED DIRECTIONAL 44 PILOT ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: 31 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - HYDRAULIC
CONTROL VALVE - BICS CONTROL
36-44 PSI (2,5-3,0 Bar) POWERED BOB-TACH
Normally Closed 17 PILOTED ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 45 RESTRICTION - 0.089 inch (2,26 mm)
4 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE - TILT CONTROL
BRONZE)
18 PILOTED ACTIVATED DIRECTIONAL 46 RESTRICTION - 0.025 inch (0,6 mm)
5 RELIEF/REPLENISHING VALVE - HIGH 33 FILTER - BICS CONTROL VALVE
CONTROL VALVE - LIFT CONTROL
PRESSURE: 5000 PSI (345 Bar) (SCREEN) 47
19 PULL BUTTON ACTIVATED RELIEF VALVE - 2000 PSI (137 Bar)
6 RELIEF VALVE - CHARGE INLET: DIRECTIONAL CONTROL VALVE - LIFT 34 CHECK VALVE - BUCKET POSITION
220-270 PSI (15,1-18,6 Bar) ARM BY-PASS 48 RELIEF VALVE - 1200 PSI (83 Bar)
VALVE
at High Engine Idle
With 140 degrees F. (60 degrees C.) Fluid 20 PILOTED ACTIVATED DIRECTIONAL 35 49 SOLENOID ACTIVATED DIRECTIONAL
RESTRICTION
CONTROL VALVE - UNLOADING CONTROL VALVE (TWO COIL)
SPOOL
7 FRONT AUXILIARY MANUAL PRESSURE 36 VARIABLE CAPACITY DISPLACEMENT 50 RELIEF VALVE - 3300 PSI (228 Bar)
BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - FLOW CONTROL 51 DUMP VALVE - (ON/OFF)
8 HYDRAULIC PUMP . . . . . . . Gear Type 16.9 GPM SPOOL 37 SHUTTLE RELIEF VALVE
(64 L/min.) at High Engine Idle (Not Adjustable - Factory Set) 62 CHECK VALVE
22 FLOW DIVIDER ADJUSTMENT VALVE 65 PSI (4,5 Bar)
9 RELIEF VALVE - MAIN: 53 AUXILIARY HYDRAULIC PUMP -
3250-3350 PSI (224-231 Bar) 23 SOLENOID ACTIVATED DIRECTIONAL 38 FIXED CAPACITY DISPLACEMENT 9.5 GPM (36 L/min) at High Engine Idle
at Front Quick Couplers CONTROL VALVE - BASE BIDIRECTIONAL HYDROSTATIC
54 CHECK VALVE - With 300 PSI (20,7 Bar) Spring with
MOTOR
10 RELIEF VALVE - PORT: . . . . . (Optional) 24 SOLENOID ACTIVATED DIRECTIONAL 0.016 inch (0,40 mm) orifice
3500 PSI (241,3 Bar) CONTROL VALVE - ROD 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring 55 HYDRAULIC BRAKE - SPRING APPLIED -
PRESSURE RELEASE
11 ANTICAVITATION VALVE
25 LOAD SHUTTLE VALVE - BLEED OFF 40 SOLENOID ACTIVATED DIRECTIONAL 56 CHECK VALVE
CONTROL VALVE - BUCKET POSITION
12 SOLENOID ACTIVATED DIRECTIONAL 26 57
SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF) RELIEF VALVE - BRAKE PRESSURE
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL 500 PSI (34,5 Bar)
13 RELIEF VALVE - PORT: . . . . . (Optional) 41 CHECK VALVE - BICS CONTROL VALVE
27 PILOT ACTIVATED DIRECTIONAL 58 SOLENOID ACTIVATED DIRECTIONAL CONTROL
3100 PSI (213,8 Bar) VALVE
CONTROL VALVE - REAR AUXILIARY 42 RELIEF VALVE - PORT:
14 LOAD CHECK VALVE 3500 PSI (241,3 Bar)
28 RESTRICTOR - 0.140 inch (3,6 mm)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.

Printed in U.S.A. V-0455legend (3-10-05)


(REAR QUICK
FEMALE COUPLERS) MALE

HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
T190 (S/N 527011001 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)

(S/N 527911001 AND ABOVE)


INTEGRATED QUICK
(PRINTED MARCH 2005) COUPLER BLOCK
23 24
V-0455 MALE
25
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
29
1 30
FEMALE
27

4 37

P-OUT P-IN T
55

32 BUCKET POSITION VALVE (OPTIONAL)

D
38 HYDRAULIC FILTER 34

31

OIL
2 22
COOLER
B HYDROSTATIC PUMPS A

5 36
5
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21

20

12 12
CHARGE 13 B
INLET B A

AUXILIARY
SPOOL
14
36
43 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C

8 51
50
52
INLET OUTLET
BRAKE VALVE B A 17
42 TILT
T 57 56 53 CYLINDER
BOB-TACH SPOOL
CYLINDER
IN (OPTIONAL) 11
HYDRAULIC
DRIVE MOTOR POWERED 14
38 BOB-TACH LIFT CYLINDERS
10
(OPTIONAL)
18
58 39 47
DR B A
LIFT
55 CYLINDER
B1 A1
SPOOL 35
54
B2 A2 48 15
46
14
37 49 45
4
PP
9 16 WORKING CIRCUITS
P1 P2 33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
44
COMPONENTS

LIFT ARM BY PASS VALVE


32
19

Printed in U.S.A. V-0455 (3-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC
T190 (S/N 527011001 AND ABOVE)
(S/N 527711001 - 527712999)
(S/N 527811001 - 527812999)
(S/N 527911001 AND ABOVE)
(PRINTED MARCH 2005)
V-0499legend
LEGEND
1 RESERVOIR:
Capacity . . . . . . . 19.2 Qt. (18,2 L) 14 LOAD CHECK VALVE 29 RESTRICTOR - 0.031 inch (0,8 mm) 43 RELIEF/ANTICAVITATION VALVE -
PORT (TILT BASE END)
2 SPRING LOADED FILTER BY-PASS 3500 PSI (241,3 Bar)
15 LIFT CYLINDER SPOOL - MADE TO 30 RELIEF VALVE: 3300 PSI (228 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar)
RESTRICT FLOW DURING BOOM 44 PILOT ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: DOWN BUT NOT DURING BOOM UP 31 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - HYDRAULIC
36-44 PSI (2,5-3,0 Bar) POWERED BOB-TACH
16 SOLENOID ACTIVATED DIRECTIONAL
Normally Closed
CONTROL VALVE - BICS CONTROL 32 FILTER - CASE DRAIN (SINTERED 45 RESTRICTION - 0.089 inch (2,26 mm)
4 DRIVE MOTOR SHUTTLE VALVE BRONZE)
17 PILOTED ACTIVATED DIRECTIONAL 46 RESTRICTION - 0.025 inch (0,6 mm)
5 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - TILT CONTROL 33 FILTER - BICS CONTROL VALVE
PRESSURE: 5000 PSI (345 Bar) (SCREEN) 47
18 PILOTED ACTIVATED DIRECTIONAL RELIEF VALVE - 2000 PSI (137 Bar)
6 RELIEF VALVE - CHARGE INLET: CONTROL VALVE - LIFT CONTROL 34 CHECK VALVE - BUCKET POSITION
220-270 PSI (15,1-18,6 Bar) 48 RELIEF VALVE - 1200 PSI (83 Bar)
19 PULL BUTTON ACTIVATED VALVE
at High Engine Idle DIRECTIONAL CONTROL VALVE - LIFT
With 140 degrees F. (49 degrees C.) Fluid 35 RESTRICTION 49 SOLENOID ACTIVATED DIRECTIONAL
ARM BY-PASS CONTROL VALVE (TWO COIL)
7 FRONT AUXILIARY MANUAL 20 PILOTED ACTIVATED DIRECTIONAL 36 VARIABLE CAPACITY DISPLACEMENT 50 CHECK VALVE - With 300 PSI (20,7 Bar)
PRESSURE BLEED-OFF VALVE CONTROL VALVE - UNLOADING BIDIRECTIONAL HYDROSTATIC PUMP Spring with 0.016 inch (0,40 mm) orifice
SPOOL
8 HYDRAULIC PUMP . . . . . . . Gear Type: 37 SHUTTLE RELIEF VALVE 51 HYDRAULIC BRAKE - SPRING APPLIED
21 PILOTED ACTIVATED DIRECTIONAL
(For S/N 527011001 & Above, S/N 527911001 (Not Adjustable - Factory Set) - PRESSURE RELEASE
CONTROL VALVE - FLOW CONTROL
& Above) 65 PSI (4,5 Bar) 52 CHECK VALVE
SPOOL
16.9 GPM (64 L/min.) at High Engine Idle
22 FLOW DIVIDER ADJUSTMENT VALVE 38 FIXED CAPACITY DISPLACEMENT 53 RELIEF VALVE - BRAKE PRESSURE
(For S/N 527711001 - 527712999, S/N BIDIRECTIONAL HYDROSTATIC 500 PSI (34,5 Bar)
527811001 - 527812999) MOTOR
23 SOLENOID ACTIVATED DIRECTIONAL 54 SOLENOID ACTIVATED DIRECTIONAL
16.3 GPM (61,7 L/min.) at High Engine Idle
CONTROL VALVE - BASE 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring CONTROL VALVE
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL
3250-3350 PSI (224-231 Bar) CONTROL VALVE - ROD 40 SOLENOID ACTIVATED DIRECTIONAL
at Front Quick Couplers CONTROL VALVE - BUCKET POSITION
10 25 LOAD SHUTTLE VALVE - BLEED OFF VALVE (ON/OFF)
RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (241,3 Bar) 41 CHECK VALVE - BICS CONTROL VALVE
26 SOLENOID ACTIVATED DIRECTIONAL
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL 42 RELIEF VALVE - PORT:
27 PILOT ACTIVATED DIRECTIONAL 3500 PSI (241,3 Bar) NOTE: Unless otherwise specified, springs have
12 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - REAR AUXILIARY NO significant pressure value.
CONTROL VALVE - AUXILIARY
13 28 RESTRICTOR - 0.140 inch (3,6 mm)
RELIEF VALVE - PORT: . . . . . (Optional)
3100 PSI (213,8 Bar)

Printed in U.S.A. V-0499legend (3-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC FEMALE
(REAR QUICK
COUPLERS) MALE

T190 (S/N 527011001 AND ABOVE)


(S/N 527711001 - 527712999) BASE ROD REAR AUX VALVE (OPTIONAL)

(S/N 527811001 - 527812999)


(S/N 527911001 AND ABOVE) INTEGRATED QUICK
(PRINTED MARCH 2005) 23 24 COUPLER BLOCK
(V-0499) 25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
29
1 30
FEMALE
27

4 37

P-OUT P-IN T
51

32 BUCKET POSITION VALVE (OPTIONAL)

D
38 HYDRAULIC FILTER 34

31

OIL
2 22
COOLER
B HYDROSTATIC PUMPS A
36 HYDRAULIC CONTROL VAVLE
5 5
A
6 3 40 C
21

13
20
12
12 AUXILIARY
CHARGE SPOOL B
INLET B A

14
36
43 TILT CYLINDERS
BICS CONTROL VALVE
5 5
D C

INLET OUTLET
TILT
BRAKE VALVE B A 17
SPOOL
T 53 52
BOB-TACH 42
CYLINDER
IN (OPTIONAL) 11
HYDRAULIC
DRIVE MOTOR POWERED 14
38 BOB-TACH LIFT CYLINDERS
(OPTIONAL)
42
18
54 39 47
DR B A LIFT
SPOOL
B1 A1 51
35
50 15
B2 A2 48
46

37 49 45 14
4
PP
33 41 33 16
9
P1 P2
44

LIFT ARM BY PASS VALVE


32
19

Printed in U.S.A.
V-0499 (3-10-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
T190 (S/N 527011001 AND ABOVE)
(S/N 527711001 - 527712999)
(S/N 527811001 - 527712999)
(S/N 527911001 AND ABOVE)
(PRINTED MARCH 2005)
V-0500legend
LEGEND
1 RESERVOIR:
Capacity . . . . . . . 19.2 Qts. (18,2 L) 14 LOAD CHECK VALVE 29 RESTRICTOR - 0.031 inch (0,8 mm) 43 RELIEF/ANTICAVITATION VALVE -
PORT (TILT BASE END)
2 SPRING LOADED FILTER BY-PASS 3500 PSI (241,3 Bar)
15 LIFT CYLINDER SPOOL - MADE TO 30 RELIEF VALVE: 3300 PSI (228 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar)
RESTRICT FLOW DURING BOOM 44 PILOT ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: DOWN BUT NOT DURING BOOM UP 31 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - HYDRAULIC
36-44 PSI (2,5-3,0 Bar) POWERED BOB-TACH
16 SOLENOID ACTIVATED DIRECTIONAL
Normally Closed
CONTROL VALVE - BICS CONTROL 32 FILTER - CASE DRAIN (SINTERED 45 RESTRICTION - 0.089 inch (2,26 mm)
4 DRIVE MOTOR SHUTTLE VALVE BRONZE)
17 PILOTED ACTIVATED DIRECTIONAL 46 RESTRICTION - 0.025 inch (0,6 mm)
5 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - TILT CONTROL 33 FILTER - BICS CONTROL VALVE
PRESSURE: 5000 PSI (345 Bar) (SCREEN) 47
18 PILOTED ACTIVATED DIRECTIONAL RELIEF VALVE - 2000 PSI (137 Bar)
6 CONTROL VALVE - LIFT CONTROL 34 CHECK VALVE - BUCKET POSITION
RELIEF VALVE - CHARGE INLET:
48 RELIEF VALVE - 1200 PSI (83 Bar)
220-270 PSI (15,1-18,6 Bar) 19 PULL BUTTON ACTIVATED VALVE
at High Engine Idle DIRECTIONAL CONTROL VALVE - LIFT
35 RESTRICTION 49 SOLENOID ACTIVATED DIRECTIONAL
With 140 degrees F. (49 degrees C.) Fluid ARM BY-PASS CONTROL VALVE (TWO COIL)
7 FRONT AUXILIARY MANUAL 20 PILOTED ACTIVATED DIRECTIONAL 36 VARIABLE CAPACITY DISPLACEMENT 50 RELIEF VALVE - 3300 PSI (228 Bar)
PRESSURE BLEED-OFF VALVE CONTROL VALVE - UNLOADING BIDIRECTIONAL HYDROSTATIC PUMP
SPOOL 51 DUMP VALVE - (ON/OFF)
8 HYDRAULIC PUMP . . . . . . . Gear Type: 37 SHUTTLE RELIEF VALVE
(For S/N 527011001 & Above, S/N 527911001 21 PILOTED ACTIVATED DIRECTIONAL
(Not Adjustable - Factory Set) 52 CHECK VALVE
& Above) CONTROL VALVE - FLOW CONTROL
65 PSI (4,5 Bar)
16.9 GPM (64 L/min.) at High Engine Idle SPOOL
53 AUXILIARY HYDRAULIC PUMP -
22 FLOW DIVIDER ADJUSTMENT VALVE 38 FIXED CAPACITY DISPLACEMENT 9.5 GPM (36 L/min) at High Engine Idle
(For S/N 527711001 - 527712999, S/N BIDIRECTIONAL HYDROSTATIC
527811001 - 527812999) 54 CHECK VALVE - With 300 PSI (20,7 Bar)
MOTOR
16.3 GPM (61,7 L/min.) at High Engine Idle 23 SOLENOID ACTIVATED DIRECTIONAL Spring with 0.016 inch (0,40 mm) orifice
CONTROL VALVE - BASE 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring 55 HYDRAULIC BRAKE - SPRING APPLIED
9 RELIEF VALVE - MAIN:
3250-3350 PSI (224-231 Bar) 24 SOLENOID ACTIVATED DIRECTIONAL - PRESSURE RELEASE
at Front Quick Couplers CONTROL VALVE - ROD 40 SOLENOID ACTIVATED DIRECTIONAL 56 CHECK VALVE
CONTROL VALVE - BUCKET POSITION
10 RELIEF VALVE - PORT: . . . . . (Optional) 57
25 LOAD SHUTTLE VALVE - BLEED OFF VALVE (ON/OFF) RELIEF VALVE - BRAKE PRESSURE
3500 PSI (241,3 Bar) 500 PSI (34,5 Bar)
41 CHECK VALVE - BICS CONTROL VALVE
11 ANTICAVITATION VALVE 26 SOLENOID ACTIVATED DIRECTIONAL 58 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO COIL 42 RELIEF VALVE - PORT: CONTROL VALVE
12 SOLENOID ACTIVATED DIRECTIONAL 27 PILOT ACTIVATED DIRECTIONAL 3500 PSI (241,3 Bar) NOTE: Unless otherwise specified, springs have
CONTROL VALVE - AUXILIARY CONTROL VALVE - REAR AUXILIARY NO significant pressure value.
13 RELIEF VALVE - PORT: . . . . . (Optional) 28 RESTRICTOR - 0.140 inch (3,6 mm)
3100 PSI (213,8 Bar)

Printed in U.S.A. V-0500legend (3-10-05)


HYDRAULIC/HYDROSTATIC SCHEMATIC FEMALE
(REAR QUICK
COUPLERS) MALE
WITH HIGH FLOW OPTION
T190 (S/N 527011001 AND ABOVE)
(S/N 527711001 - 527712999) BASE ROD REAR AUX VALVE (OPTIONAL)

(S/N 527811001 - 527812999)


(S/N 527911001 AND ABOVE) INTEGRATED QUICK
(PRINTED MARCH 2005) 23 24 COUPLER BLOCK
(V-0500) 25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
29
1 30
FEMALE
27

4 37

P-OUT P-IN T
55

32 BUCKET POSITION VALVE (OPTIONAL)

D
38 HYDRAULIC FILTER 34

31

OIL
2 22
COOLER
B HYDROSTATIC PUMPS A

5 36
5
HYDRAULIC CONTROL VAVLE A
6 3 40 C
21

13
20
12
12 AUXILIARY
CHARGE SPOOL B
INLET B A

14
36
43 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C

8 51
50
52
INLET OUTLET
TILT
BRAKE VALVE B A 17
SPOOL
T 57 56 53
BOB-TACH
42
CYLINDER
IN (OPTIONAL) 11
HYDRAULIC
DRIVE MOTOR POWERED 14
38 BOB-TACH LIFT CYLINDERS
(OPTIONAL) 42
18
58 39 47
DR B A LIFT
SPOOL
B1 A1 55
35
54 15
B2 A2 48
46

37 49 45 14
4
PP
33 16
9 33
P2 41
P1
44

LIFT ARM BY PASS VALVE


32
19

Printed in U.S.A.
V-0500 (3-10-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC

T190 (S/N 527713000 AND ABOVE)


(S/N 527813000 AND ABOVE)

(PRINTED MARCH 2005)


V-0563legend
LEGEND
1 RESERVOIR:
Capacity . . . . . . . 19.2 Qt. (18,2 L) 15 LIFT CYLINDER SPOOL - MADE TO 29 RESTRICTOR - 0.031 inch (0,8 mm) 43 PORT RELIEF/ANTICAVITATION VALVE
RESTRICT FLOW DURING BOOM 3500 PSI (241,3 Bar)
2 SPRING LOADED FILTER BY-PASS DOWN BUT NOT DURING BOOM UP 30 RELIEF VALVE: 3300 PSI (228 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar)
16 SOLENOID ACTIVATED DIRECTIONAL 44 PILOT ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: 31 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - HYDRAULIC
CONTROL VALVE - BICS CONTROL
36-44 PSI (2,5-3,0 Bar) POWERED BOB-TACH
Normally Closed 17 PILOTED ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 45 RESTRICTION - 0.089 inch (2,26 mm)
4 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE - TILT CONTROL
BRONZE)
18 PILOTED ACTIVATED DIRECTIONAL 46 RESTRICTION - 0.025 inch (0,6 mm)
5 RELIEF/REPLENISHING VALVE - HIGH 33 FILTER - BICS CONTROL VALVE
CONTROL VALVE - LIFT CONTROL
PRESSURE: 5000 PSI (345 Bar) (SCREEN) 47
19 PULL BUTTON ACTIVATED RELIEF VALVE - 2000 PSI (137 Bar)
6 RELIEF VALVE - CHARGE INLET: DIRECTIONAL CONTROL VALVE - LIFT 34 CHECK VALVE - BUCKET POSITION
220-270 PSI (15,1-18,6 Bar) ARM BY-PASS 48 RELIEF VALVE - 1200 PSI (83 Bar)
VALVE
at High Engine Idle
20 PILOTED ACTIVATED DIRECTIONAL 35 49 SOLENOID ACTIVATED DIRECTIONAL
With 140 degrees F. (49 degrees C.) Fluid RESTRICTION
CONTROL VALVE - UNLOADING CONTROL VALVE (TWO COIL)
SPOOL
7 FRONT AUXILIARY MANUAL 36 VARIABLE CAPACITY DISPLACEMENT 50 CHECK VALVE - With 300 PSI (20,7 Bar)
PRESSURE BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP Spring with 0.016 inch (0,40 mm) orifice
CONTROL VALVE - FLOW CONTROL
8 HYDRAULIC PUMP . . . . . . . Gear Type SPOOL 37 SHUTTLE RELIEF VALVE 51 HYDRAULIC BRAKE - SPRING APPLIED
16.3 GPM (61,7 L/min.) at High Engine Idle (Not Adjustable - Factory Set) - PRESSURE RELEASE
22 FLOW DIVIDER ADJUSTMENT VALVE 65 PSI (4,5 Bar) 52 CHECK VALVE
9 RELIEF VALVE - MAIN:
3250-3350 PSI (224-231 Bar) 23 SOLENOID ACTIVATED DIRECTIONAL 38 FIXED CAPACITY DISPLACEMENT 53 RELIEF VALVE - BRAKE PRESSURE
at Front Quick Couplers CONTROL VALVE - BASE BIDIRECTIONAL HYDROSTATIC 500 PSI (34,5 Bar)
MOTOR
10 RELIEF VALVE - PORT: . . . . . (Optional) 24 SOLENOID ACTIVATED DIRECTIONAL 54 FILTER - Bob-Tach Valve
3500 PSI (241,3 Bar) CONTROL VALVE - ROD 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring (S/N 527714886 & Above Only)
(S/N 527813188 & Above Only)
11 ANTICAVITATION VALVE
25 LOAD SHUTTLE VALVE - BLEED OFF 40 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
12 SOLENOID ACTIVATED DIRECTIONAL 26 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF)
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL
13 RELIEF VALVE - PORT: . . . . . (Optional) 41 CHECK VALVE - BICS CONTROL VALVE
27 PILOT ACTIVATED DIRECTIONAL
3100 PSI (213,8 Bar)
CONTROL VALVE - REAR AUXILIARY 42 SOLENOID ACTIVATED DIRECTIONAL
14 LOAD CHECK VALVE CONTROL VALVE
28 RESTRICTOR - 0.140 inch (3,6 mm) NOTE: Unless otherwise specified, springs have
NO significant pressure value.

Printed in U.S.A. V-0563legend (3-10-05)


(REAR QUICK
FEMALE COUPLERS) MALE
HYDRAULIC/HYDROSTATIC SCHEMATIC

T190 (S/N 527713000 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)

(S/N 527813000 AND ABOVE)


(PRINTED MARCH 2005)
INTEGRATED QUICK
(V-0563) COUPLER BLOCK
23 24

25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
29
1 30
FEMALE
27

4 37

P-OUT P-IN T
51

32 BUCKET POSITION VALVE (OPTIONAL)

D
38 HYDRAULIC FILTER 34

31

OIL
2 22
COOLER
B HYDROSTATIC PUMPS A

5 36
5
HYDRAULIC CONTROL VAVLE A
6 3 40 C
21

13
20
12
12 AUXILIARY
CHARGE SPOOL B
INLET B A

14
36
43 TILT CYLINDERS
BICS CONTROL VALVE
5 5
D C

INLET OUTLET
TILT
BRAKE VALVE B A 17
SPOOL
T 53 52
BOB-TACH
CYLINDER
IN (OPTIONAL) 43 11
HYDRAULIC
DRIVE MOTOR POWERED 14
38 BOB-TACH LIFT CYLINDERS
(OPTIONAL) 43
18
42 39 47
DR B A LIFT
SPOOL
B1 A1 51
35
50 15
B2 A2 48
46

49 33 41
4 37 45 14
PP
54 33
9 16
P1 P2
44

LIFT ARM BY PASS VALVE


32
19

Printed in U.S.A.
V-0563 (3-10-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
T190 (S/N 527713000 AND ABOVE)
(S/N 527813000 AND ABOVE)

(PRINTED MARCH 2005)


V-0564legend
LEGEND
1 RESERVOIR:
Capacity . . . . . . . 19.2 Qts. (18,2 L) 15 LIFT CYLINDER SPOOL - MADE TO 29 RESTRICTOR - 0.031 inch (0,8 mm) 43 PORT RELIEF/ANTICAVITATION VALVE
RESTRICT FLOW DURING BOOM 3500 PSI (241,3 Bar)
2 SPRING LOADED FILTER BY-PASS DOWN BUT NOT DURING BOOM UP 30 RELIEF VALVE: 3300 PSI (228 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar)
16 SOLENOID ACTIVATED DIRECTIONAL 44 PILOT ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: 31 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - HYDRAULIC
CONTROL VALVE - BICS CONTROL
36-44 PSI (2,5-3,0 Bar) POWERED BOB-TACH
Normally Closed 17 PILOTED ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 45 RESTRICTION - 0.089 inch (2,26 mm)
4 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE - TILT CONTROL
BRONZE)
18 PILOTED ACTIVATED DIRECTIONAL 46 RESTRICTION - 0.025 inch (0,6 mm)
5 RELIEF/REPLENISHING VALVE - HIGH 33 FILTER - BICS CONTROL VALVE
CONTROL VALVE - LIFT CONTROL
PRESSURE: 5000 PSI (345 Bar) (SCREEN) 47
19 PULL BUTTON ACTIVATED RELIEF VALVE - 2000 PSI (137 Bar)
6 RELIEF VALVE - CHARGE INLET: DIRECTIONAL CONTROL VALVE - LIFT 34 CHECK VALVE - BUCKET POSITION
ARM BY-PASS 48 RELIEF VALVE - 1200 PSI (83 Bar)
220-270 PSI (15,1-18,6 Bar) VALVE
at High Engine Idle 20 PILOTED ACTIVATED DIRECTIONAL 35 RESTRICTION 49 SOLENOID ACTIVATED DIRECTIONAL
With 140 degrees F. (49 degrees C.) Fluid CONTROL VALVE - UNLOADING CONTROL VALVE (TWO COIL)
SPOOL
7 FRONT AUXILIARY MANUAL 36 VARIABLE CAPACITY DISPLACEMENT 50 RELIEF VALVE - 3300 PSI (228 Bar)
PRESSURE BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - FLOW CONTROL 51 DUMP VALVE - (ON/OFF)
8 HYDRAULIC PUMP . . . . . . . Gear Type 16.3 37
SPOOL SHUTTLE RELIEF VALVE
GPM (61,7 L/min.) at High Engine Idle (Not Adjustable - Factory Set) 52 CHECK VALVE
22 FLOW DIVIDER ADJUSTMENT VALVE 65 PSI (4,5 Bar)
9 RELIEF VALVE - MAIN: 53 AUXILIARY HYDRAULIC PUMP -
3250-3350 PSI (224-231 Bar) 23 SOLENOID ACTIVATED DIRECTIONAL 38 FIXED CAPACITY DISPLACEMENT 9.5 GPM (36 L/min) at High Engine Idle
at Front Quick Couplers CONTROL VALVE - BASE BIDIRECTIONAL HYDROSTATIC
54 CHECK VALVE - With 300 PSI (20,7 Bar)
MOTOR
10 RELIEF VALVE - PORT: . . . . . (Optional) 24 SOLENOID ACTIVATED DIRECTIONAL Spring with 0.016 inch (0,40 mm) orifice
3500 PSI (241,3 Bar) CONTROL VALVE - ROD 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring 55 HYDRAULIC BRAKE - SPRING APPLIED
- PRESSURE RELEASE
11 ANTICAVITATION VALVE
25 LOAD SHUTTLE VALVE - BLEED OFF 40 SOLENOID ACTIVATED DIRECTIONAL 56 CHECK VALVE
CONTROL VALVE - BUCKET POSITION
12 SOLENOID ACTIVATED DIRECTIONAL 26 57
SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF) RELIEF VALVE - BRAKE PRESSURE
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL 500 PSI (34,5 Bar)
13 RELIEF VALVE - PORT: . . . . . (Optional) 41 CHECK VALVE - BICS CONTROL VALVE
27 PILOT ACTIVATED DIRECTIONAL 58 FILTER - Bob-Tach Valve
3100 PSI (213,8 Bar)
CONTROL VALVE - REAR AUXILIARY (S/N 527714886 & Above Only)
42 SOLENOID ACTIVATED DIRECTIONAL
14 LOAD CHECK VALVE (S/N 527813188 & Above Only)
28 RESTRICTOR - 0.140 inch (3,6 mm) CONTROL VALVE

NOTE: Unless otherwise specified, springs have


NO significant pressure value.

Printed in U.S.A. V-0564legend (3-10-05)


(REAR QUICK
FEMALE COUPLERS) MALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
T190 (S/N 527713000 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)

(S/N 527813000 AND ABOVE)


(PRINTED MARCH 2005)
INTEGRATED QUICK
(V-0564) COUPLER BLOCK
23 24

25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
29
1 30
FEMALE
27

4 37

P-OUT P-IN T
55

32 BUCKET POSITION VALVE (OPTIONAL)

D
38 HYDRAULIC FILTER 34

31

OIL
2 22
COOLER
B HYDROSTATIC PUMPS A

5 36
5
A
HYDRAULIC CONTROL VALVE
6 3 40 C
21

13
20
12
12 AUXILIARY
CHARGE SPOOL B
INLET B A

14
36
43 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C

8 51
50
52
INLET OUTLET
TILT
BRAKE VALVE B A 17
SPOOL
T 57 56 53
BOB-TACH
CYLINDER
IN (OPTIONAL) 43 11
HYDRAULIC
DRIVE MOTOR POWERED 14
38 BOB-TACH LIFT CYLINDERS
(OPTIONAL)
43
18
42 39 47
DR B A LIFT
SPOOL
B1 A1 55
35
54 15
B2 A2 48
46

49 33 41
4 37 45 14
PP
58
33 16
9
P1 P2
44

LIFT ARM BY PASS VALVE


32
19

Printed in U.S.A.
V-0564 (3-10-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC
With SJC Option
T190 (S/N 527713000 AND ABOVE)
(S/N 527813000 AND ABOVE)

(PRINTED MAY 2005)


V-0695legend
LEGEND
1 RESERVOIR:
Capacity . . . . . . . 19.2 qt. (18,2 L) 15 LIFT CYLINDER SPOOL - MADE TO 29 RESTRICTOR - 0.031 inch (0,8 mm) 43 PORT RELIEF/ANTICAVITATION VALVE
RESTRICT FLOW DURING BOOM 3500 PSI (241,3 bar)
2 SPRING LOADED FILTER BY-PASS DOWN BUT NOT DURING BOOM UP 30 RELIEF VALVE: 3300 PSI (228 bar)
VALVE: 45-55 PSI (3,1-3,8 bar)
16 SOLENOID ACTIVATED DIRECTIONAL 44 PILOT ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: 31 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - HYDRAULIC
CONTROL VALVE - BICS CONTROL
36-44 PSI (2,5-3,0 bar) POWERED BOB-TACH
Normally Closed 17 PILOTED ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 45 RESTRICTION - 0.089 inch (2,26 mm)
4 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE - TILT CONTROL
BRONZE)
18 PILOTED ACTIVATED DIRECTIONAL 46 RESTRICTION - 0.025 inch (0,6 mm)
5 RELIEF/REPLENISHING VALVE - HIGH 33 FILTER - BICS CONTROL VALVE
CONTROL VALVE - LIFT CONTROL
PRESSURE: 5250 PSI (362 bar) (SCREEN) 47
19 PULL BUTTON ACTIVATED RELIEF VALVE - 2000 PSI (137 bar)
6 RELIEF VALVE - CHARGE INLET: DIRECTIONAL CONTROL VALVE - LIFT 34 CHECK VALVE - BUCKET POSITION
360 PSI (24,8 bar) ARM BY-PASS 48 RELIEF VALVE - 1200 PSI (83 bar)
VALVE
at High Engine Idle
20 PILOTED ACTIVATED DIRECTIONAL 35 49 SOLENOID ACTIVATED DIRECTIONAL
With 140 degrees F. (60 degrees C.) Fluid RESTRICTION
CONTROL VALVE - UNLOADING CONTROL VALVE (TWO COIL)
SPOOL
7 FRONT AUXILIARY MANUAL 36 VARIABLE CAPACITY DISPLACEMENT 50 CHECK VALVE - With 300 PSI (20,7 bar) Spring
PRESSURE BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP with 0.016 inch (0,40 mm) orifice
CONTROL VALVE - FLOW CONTROL
8 HYDRAULIC PUMP . . . . . . . Gear Type SPOOL 37 SHUTTLE RELIEF VALVE 51 HYDRAULIC BRAKE - SPRING APPLIED
16.3 GPM (61,7 L/min.) at High Engine Idle (Not Adjustable - Factory Set) - PRESSURE RELEASE
22 FLOW DIVIDER ADJUSTMENT VALVE 65 PSI (4,5 bar) 52 CHECK VALVE
9 RELIEF VALVE - MAIN:
3250-3350 PSI (224-231 bar) 23 SOLENOID ACTIVATED DIRECTIONAL 38 FIXED CAPACITY DISPLACEMENT 53 RELIEF VALVE - BRAKE PRESSURE
at Front Quick Couplers CONTROL VALVE - BASE BIDIRECTIONAL HYDROSTATIC 500 PSI (34,5 bar)
MOTOR
10 RELIEF VALVE - PORT: . . . . . (Optional) 24 SOLENOID ACTIVATED DIRECTIONAL 54 FILTER - Bob-Tach Valve
3500 PSI (241,3 bar) CONTROL VALVE - ROD 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring
55 CHARGE PUMP . . . . . . . Gear Type
11 ANTICAVITATION VALVE 12.8 GPM (48,5 L/min.) at High Engine Idle
25 LOAD SHUTTLE VALVE - BLEED OFF 40 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION 56 SOLENOID ACTIVATED CONTROL
12 SOLENOID ACTIVATED DIRECTIONAL 26 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF) VALVE - FORWARD/REVERSE
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL
41 CHECK VALVE - BICS CONTROL VALVE 57 SERVO PISTON - Swash Plate
13 RELIEF VALVE - PORT: . . . . . (Optional)
27 PILOT ACTIVATED DIRECTIONAL
3100 PSI (213,8 bar)
CONTROL VALVE - REAR AUXILIARY 42 SOLENOID ACTIVATED DIRECTIONAL 58 POSITION SENSOR - Swash Plate
14 LOAD CHECK VALVE CONTROL VALVE
28 RESTRICTOR - 0.140 inch (3,6 mm) 59 CHARGE PRESSURE SWITCH

NOTE: Unless otherwise specified, springs have


NO significant pressure value.

Printed in U.S.A. V-0695legend (5-4-05)


(REAR QUICK
FEMALE COUPLERS) MALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC OPTION
T190 (S/N 527713000 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)

(S/N 527813000 AND ABOVE)


(PRINTED MAY 2005)
INTEGRATED QUICK
(V-0695) COUPLER BLOCK
23 24

25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR 29
1 30
FEMALE
27

4 37

P-OUT P-IN T
51

32 BUCKET POSITION VALVE (OPTIONAL)

D
38 HYDRAULIC FILTER 34

31

B HYDROSTATIC PUMPS A OIL


COOLER 22
2
56

57 A
HYDRAULIC CONTROL VALVE
5 5 3 40 C
58
21

6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A

59

58 14
2 31 36
43 TILT CYLINDERS
BICS CONTROL VALVE

5 57 5
56

3
TILT
B A 17
SPOOL
D C

8
43 11

INLET 14
LIFT CYLINDERS
55 43
18
OUTLET HYDRAULIC
53
IN POWERED B
T A LIFT
BOB-TACH
52 SPOOL
(OPTIONAL)
38
35
39 47
15
DR

14
54
51
42 48 33 41
46 33 16
9
49 45
B1 A1
37 PP
4 58
B2 A2
P2 LIFT ARM BY PASS VALVE
BRAKE VALVE P1
32 44 19
Printed in U.S.A.

DRIVE MOTOR
V-0695 (5-5-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND HIGH FLOW OPTION
T190 (S/N 527713000 AND ABOVE)
(S/N 527813000 AND ABOVE)
(PRINTED MAY 2005)
V-0696legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 47 RELIEF VALVE - 2000 PSI (137 bar)
Capacity . . . . . . . 19.2 qt. (18,2 L) CONTROL VALVE - BICS CONTROL BRONZE)
2 SPRING LOADED FILTER BY-PASS 48 RELIEF VALVE - 1200 PSI (83 bar)
17 PILOTED ACTIVATED DIRECTIONAL 33 FILTER - BICS CONTROL VALVE
VALVE: 45-55 PSI (3,1-3,8 bar)
CONTROL VALVE - TILT CONTROL (SCREEN) 49 SOLENOID ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE (TWO COIL)
36-44 PSI (2,5-3,0 bar) 18 PILOTED ACTIVATED DIRECTIONAL 34 CHECK VALVE - BUCKET POSITION
Normally Closed CONTROL VALVE - LIFT CONTROL VALVE 50 RELIEF VALVE - 3300 PSI (228 bar)

4 DRIVE MOTOR SHUTTLE VALVE 19 PULL BUTTON ACTIVATED 51


35 RESTRICTION DUMP VALVE - (ON/OFF)
DIRECTIONAL CONTROL VALVE -
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS 52 CHECK VALVE
36 VARIABLE CAPACITY DISPLACEMENT
PRESSURE: 5250 PSI (362 bar) 20 PILOTED ACTIVATED DIRECTIONAL BI-DIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 53 AUXILIARY HYDRAULIC PUMP -
6 RELIEF VALVE - CHARGE INLET: SPOOL 37 SHUTTLE RELIEF VALVE 9.5 GPM (36 L/min) at High Engine Idle
360 PSI (24,8 bar) (Not Adjustable - Factory Set) 54
21 PILOTED ACTIVATED DIRECTIONAL CHECK VALVE - With 300 PSI (20,7 bar) Spring
at High Engine Idle 65 PSI (4,5 bar)
CONTROL VALVE - FLOW CONTROL with 0.016 inch (0,40 mm) orifice
With 140 degrees F. (60 degrees C.) Fluid
SPOOL 55 HYDRAULIC BRAKE - SPRING APPLIED
38 FIXED CAPACITY DISPLACEMENT
7 FRONT AUXILIARY MANUAL BI-DIRECTIONAL HYDROSTATIC - PRESSURE RELEASE
22 FLOW DIVIDER ADJUSTMENT VALVE
PRESSURE BLEED-OFF VALVE MOTOR 56 CHECK VALVE
8 HYDRAULIC PUMP . . . . . . . Gear Type 16.3 23 SOLENOID ACTIVATED DIRECTIONAL 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring 57 RELIEF VALVE - BRAKE PRESSURE
GPM (61,7 L/min.) at High Engine Idle
CONTROL VALVE - BASE 500 PSI (34,5 bar)
24 SOLENOID ACTIVATED DIRECTIONAL 40 SOLENOID ACTIVATED DIRECTIONAL 58
9 RELIEF VALVE - MAIN: FILTER - Bob-Tach Valve
CONTROL VALVE - ROD CONTROL VALVE - BUCKET POSITION
3250-3350 PSI (224-231 bar)
VALVE (ON/OFF) 59
at Front Quick Couplers CHARGE PUMP -
25 LOAD SHUTTLE VALVE - BLEED OFF 41 CHECK VALVE - BICS CONTROL VALVE 12.8 GPM (48,5 L/min) at High Engine Idle
10 RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (241,3 bar) 26 SOLENOID ACTIVATED DIRECTIONAL 60 SOLENOID ACTIVATED CONTROL
42 SOLENOID ACTIVATED DIRECTIONAL VALVE - FORWARD/REVERSE
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL
CONTROL VALVE
27 PILOT ACTIVATED DIRECTIONAL 61 SERVO PISTON -Swash Plate
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 43 PORT RELIEF/ANTICAVITATION VALVE
3500 PSI (241,3 bar) 62 POSITION SENSOR -Swash Plate
CONTROL VALVE - AUXILIARY
28 RESTRICTOR - 0.140 inch (3,6 mm)
13 RELIEF VALVE - PORT: . . . . . (Optional) 44 PILOT ACTIVATED DIRECTIONAL 63 CHARGE PRESSURE SWITCH
3100 PSI (213,8 bar) 29 RESTRICTOR - 0.031 inch (0,8 mm) CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
14 LOAD CHECK VALVE
30 RELIEF VALVE: 3300 PSI (228 bar) 45 RESTRICTION - 0.089 inch (2,26 mm)
15 LIFT CYLINDER SPOOL - MADE TO NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER) 46 RESTRICTION - 0.025 inch (0,6 mm)
RESTRICT FLOW DURING BOOM NO significant pressure value.
DOWN BUT NOT DURING BOOM UP
V-0696legend (5-4-05)

Printed in U.S.A.
(REAR QUICK
FEMALE COUPLERS) MALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND HIGH FLOW OPTION
T190 (S/N 527713000 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)

(S/N 527813000 AND ABOVE)


(PRINTED MAY 2005)
INTEGRATED QUICK
(V-0696) COUPLER BLOCK
23 24

25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR 29
1 30
FEMALE
27

4 37

P-OUT P-IN T
55

32 BUCKET POSITION VALVE (OPTIONAL)

D
38 HYDRAULIC FILTER 34

31

B HYDROSTATIC PUMPS A OIL


COOLER 22
2
60

61 A
HYDRAULIC CONTROL VALVE
5 5 3 40 C
62
21

6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A

63

62 14
2 31 36
43 TILT CYLINDERS
BICS CONTROL VALVE
HIGH FLOW VALVE
5 61 5
60 51
50
3 52
TILT
B A 17
SPOOL
D C

8
43 11

INLET 14
LIFT CYLINDERS
59 43
18
HYDRAULIC
57 OUTLET
IN 53 POWERED B
T A LIFT
BOB-TACH
56 SPOOL
(OPTIONAL)
38
35
39 47
15
DR

14
54
55
42 48 33 41
46 33 16
9
49 45
B1 A1
37 PP
4 58
B2 A2
P2 LIFT ARM BY PASS VALVE
BRAKE VALVE P1
32 44 19
Printed in U.S.A.

DRIVE MOTOR
V-0696 (5-4-05)
HYDRAULIC SYSTEM INFORMATION

T190 Bobcat Loader


20-10-1 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)

T190 Bobcat Loader


20-10-2 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT'D)

T190 Bobcat Loader


20-10-3 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT'D)

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

PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
The transmission warning light come ON when hydraulics are operating. 1, 3
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM 1, 3, 4, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position 4
The lift arms come down with the pedal is in neutral position 4, 9, 10, 11
By-pass valve stuck 12
By-pass valve stem bent or broke 13

KEY TO CORRECT CAUSE

1. The fluid level is not correct.


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

T190 Bobcat Loader


20-10-5 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT'D)

Tighten Procedures

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

For tightening torques for hydraulic fittings,


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

T190 Bobcat Loader


20-10-6 Service Manual
CYLINDER (LIFT) Figure 20-20-2

Checking

WARNING
2
Diesel fuel or hydraulic fluid under pressure can 1
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496 N-18786

Figure 20-20-1 Install a plug in the hose (Item 1) [Figure 20-20-2] and
tighten.

Connect the negative ground cable to the battery.

Engage the parking brake. Lower the seat bar. Start the
engine. Press the PRESS TO OPERATE BUTTON. Push
the top (toe) of the lift pedal.
1
If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-20-2], remove the lift cylinder for
repair.

Repeat the procedure to check the other lift cylinder.

N-18785

Lower the lift arms. Stop the engine. Pull up on the lift WARNING
arm by-pass control and move the lift pedal to release the
hydraulic pressure. Raise the seat bar. Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Check only one cylinder at a time. Open the rear door. Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
Disconnect the negative ground cable to the battery. W-2103-1285

Disconnect the hose (Item 1) [Figure 20-20-1] from the


lift cylinder base end port.

T190 Bobcat Loader


20-20-1 Service Manual
CYLINDER (LIFT) (CONT’D) Figure 20-20-4

Removal And Installation


1
Figure 20-20-3
2

N-18806

Remove the retainer bolt (Item 1) [Figure 20-20-4] and


N-18785 nut from the lift arm pin (both sides).

Installation: Tighten the bolt and nut to standard torque.


Stop the engine. Pull up on the lift arm by-pass control to
release the hydraulic pressure. Use a drift pin and hammer, remove the lift arm pivot pin
(Item 2) [Figure 20-20-4] (both sides).
Open the rear door.
Roll the lift arm link back.
Disconnect the negative ground cable to the battery.
Figure 20-20-5
Disconnect the hose (Item 1) [Figure 20-20-3] from the
lift cylinder base end port.

Install a plug in the hose and tighten.


1

P-34048A

Remove the retainer bolt (Item 1) [Figure 20-20-5] and


nut from the lift cylinder rod end pivot pin (both sides).

Installation: Tighten the bolt and nut to standard torque.

T190 Bobcat Loader


20-20-2 Service Manual
CYLINDER (LIFT) (CONT’D) Figure 20-20-8

Removal And Installation (Cont’d)

Figure 20-20-6 1

2
1

P-24707

Remove the retainer bolt (Item 1) [Figure 20-20-8] and


P-34049A nut from the lift cylinder pivot pin.

Installation: Tighten the bolt and nut to standard torque.


Use a slide hammer, remove the lift cylinder rod end pivot
pin (Item 1) [Figure 20-20-6]. Use a drift pin and hammer, remove the lift arm pivot pin
(Item 2) [Figure 20-20-8].
Figure 20-20-7
Figure 20-20-9

P-34047A
1

Install a smaller pin (Item 1) [Figure 20-20-7] to hold the


cylinder in place.

Disconnect the hose (item 2) [Figure 20-20-7] from the


lift cylinder rod end port.

Install a plug in the hose and tighten.

P-24721

Remove the smaller pin (Item 1) [Figure 20-20-7] and lift


the lift cylinder (Item 1) [Figure 20-20-9] out from the
loader.

T190 Bobcat Loader


20-20-3 Service Manual
CYLINDER (LIFT) (CONT’D)

Identification

1. Plug 9. Spacer
2. O-ring 10. Seal
3. Cylinder 11. O-ring
4. O-ring 12. Head
5. Nut 13. Rod Seal
6. Piston 14. Wiper Seal
7. Seal 15. Rod
8. O-ring

7 8
1 6
15
2
5
4

14
1 13
2 12
3
11

10

B-13593

T190 Bobcat Loader


20-20-4 Service Manual
CYLINDER (LIFT) (CONT’D) Figure 20-20-12

Disassembly
2
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook 1


Spanner Wrench

Hold the hydraulic cylinder over a drain pan and move


the rod in and out slowly to remove the fluid from the
cylinder.

Put the base end of the cylinder in a vise. 3

Figure 20-20-10 P-48038

1 Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-


20-12] from the piston.

NOTE: If the fiber surface (Item 3) [Figure 20-20-12]


on the piston head, becomes damaged, the
complete piston head must be replaced.

Figure 20-20-13

P-48033

Use a spanner wrench to loosen the head (Item 1)


[Figure 20-20-10] from the cylinder case.
2
Figure 20-20-11

4
3 P-48039
2

1 Remove the two O-rings (Item 1) and the back-up washer


(Item 2) [Figure 20-20-13] from the cylinder head.

P-48036

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

T190 Bobcat Loader


20-20-5 Service Manual
CYLINDER (LIFT) (CONT'D) Assembly

Disassembly (Cont'd) Use the following tools to assemble the cylinder:

Figure 20-20-14 MEL1396 - Seal Installation Tool


MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench

1 Figure 20-20-16

P-48040

Remove the wiper seal (Item 1) [Figure 20-20-14] from


the cylinder head.
P7424
Figure 20-20-15

Wash the cylinder parts in solvent and air dry them.

Inspect the cylinder parts for nicks, scratches or other


damage. Replace any damaged parts.

Always install new O-rings and seals during assembly.


1
Lubricate all O-rings and seals with hydraulic oil during
installation.

Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-16].

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


on the piston.
Remove the rod seal (Item 1) [Figure 20-20-15] from the
cylinder head.

T190 Bobcat Loader


20-20-6 Service Manual
CYLINDER (LIFT) (CONT'D) Figure 20-20-19

Assembly (Cont'd)

Figure 20-20-17

1
2

P7425

Install the rod seal in the head [Figure 20-20-19].


P-48038
Figure 20-20-20

Install the O-ring (Item 1) and seal (Item 2) [Figure 20-


20-17] on the cylinder piston.
2
Figure 20-20-18

P-48041 P-48042

Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-20-
P-48043 P7427 20].

Install the rod seal on the rod seal tool [Figure 20-20-18].

NOTE: During installation the spring side of the seal


(Item 1) [Figure 20-20-18] must be installed
toward the inside of the cylinder.

Rotate the handles to collapse the rod seal [Figure 20-


20-18].

T190 Bobcat Loader


20-20-7 Service Manual
CYLINDER (LIFT) (CONT'D)

Assembly (Cont'd)

Figure 20-20-21

1
2 3

P-48036

NOTE: Clean and dry the threads before installing the


nut. Install the new nut from the kit.

Install the head (Item 1), spacer (Item 2) piston (Item 3),
and nut (Item 4) [Figure 20-20-21].

Tighten the nut (Item 4) [Figure 20-20-21] to 600 ft.-lbs.


(814 Nm) torque.

Figure 20-20-22

P-48035

Put the base end of the hydraulic cylinder in a vise.

Tighten the head (Item 1) [Figure 20-20-22] using a


spanner wrench.

T190 Bobcat Loader


20-20-8 Service Manual
CYLINDER (TILT) Remove the attachment. Roll the Bob-Tach fully back.
Stop the engine. Raise the seat bar.
Checking
Disconnect the hose (Item 1) [Figure 20-21-1] which
goes to the base end of the tilt cylinder.

WARNING Install a cap (Item 1) [Figure 20-21-2] on the fitting and


tighten.
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by Engage the parking brake. Lower the seat bar.
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a Start the engine and push the Press to Operate button.
physician familiar with this injury is not received Push the bottom (heel) of the tilt pedal.
immediately.
W-2145-0290 If there is leakage from the open port, remove the tilt
cylinder for repair.
Figure 20-21-1

N-18801

Figure 20-21-2

N-18802

T190 Bobcat Loader


20-21-1 Service Manual
CYLINDER (TILT) (CONT'D) Figure 20-21-4

Removal And Installation

WARNING 1

Always clean up spilled fuel or oil. Keep heat, flames,


sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285

Figure 20-21-3 N-18545

Use a drift pin and hammer, remove the rod end pivot pin
(Item 1) [Figure 20-21-4].

Figure 20-21-5
1

N-18544
3 2
Remove the attachment. Roll the Bob-Tach forward. Stop
the engine. Raise the seat bar.

Remove the retainer bolt (Item 1) [Figure 20-21-3] and


nut from the rod end pin. P-34137

Installation: Tighten the bolt and nut to standard torque.


Remove the retainer bolt (Item 1) [Figure 20-21-5] from
the tilt cylinder rod end pivot pin.

Installation: Tighten the bolt and nut to 125-140 ft.-lbs.


(170-190 Nm) torque.

Remove the step (Item 2) [Figure 20-21-5].

Disconnect the hose (Item 3) [Figure 20-21-5] from the


cylinders.

T190 Bobcat Loader


20-21-2 Service Manual
CYLINDER (TILT) (CONT'D) Base End Pivot Pin Replacement

Removal And Installation (Cont’d) Figure 20-21-7

Figure 20-21-6

2
P-24709

P-34228
Remove the tilt cylinder from the Bob-Tach. (See
Removal And Installation, Page 20-20-2.)
Disconnect the hose (Item 1) [Figure 20-21-6] from the
cylinder. Loosen the retainer bolt (Item 1) [Figure 20-21-7] from
the tilt cylinder rod base end pin.
Remove the cylinder (Item 2) [Figure 20-21-6] from the
rod end pivot pin. Installation: Tighten the retainer bolt to 175-190 ft.-lbs.
(240-260 Nm) torque.
Remove the cylinder from the loader.
Strike the head of the bolt (Item 1) [Figure 20-21-7] to
push the pivot pin out.

Reverse the removal procedure to install the pivot pin.

T190 Bobcat Loader


20-21-3 Service Manual
CYLINDER (TILT) (CONT'D) Figure 20-21-10

Rod End Pivot Pin Bushing And Seal Replacement

Figure 20-21-8

1
1
N-18554

Reverse the removal procedure to install the pivot pin


N-18556 bushing and seal.

Remove the rod end of the tilt cylinder from the Bob-
Tach. (See Rod End Pivot Pin Bushing And Seal
Replacement, Page 20-21-4.)

Use a seal pick to remove the seals (Item 1) [Figure 20-


21-8] on both sides of the pivot bushing.

Figure 20-21-9

N-18555

Remove and replace bushing with a driver tool and


hammer [Figure 20-21-9].

T190 Bobcat Loader


20-21-4 Service Manual
CYLINDER (TILT) (CONT'D)

Parts Identification

1. Case 9. Washer
2. Plug 10. O-ring
3. O-ring 11. Head
4. Nut 12. Seal
5. Piston 13. Seal
6. Seal 14. Rod
7. O-ring 15. Seal MC-1688B
8. O-ring 16. Bushing

3
MC-01688A

4
10

7
12

6 13

5 11

MC-01688D
14

MC-01688C
15
16
15

PE-1056A

T190 Bobcat Loader


20-21-5 Service Manual
CYLINDER (TILT) (CONT'D) Figure 20-21-13

Disassembly
2
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook 1


Spanner Wrench

Hold the hydraulic cylinder over a drain pan and move


the rod in and out slowly to remove the fluid from the
cylinder.

Put the base end of the cylinder in a vise.

Figure 20-21-11 P-48073

Remove the seal (Item 1), and O-ring (Item 2) [Figure


20-21-13] from the piston.
1
Figure 20-21-14

2
P-48034

Use a spanner wrench to loosen the head (Item 1)


[Figure 20-21-11] from the cylinder case.

Figure 20-21-12 P-48039

3 Remove the two O-rings (Item 1) and the back-up washer


2 (Item 2) [Figure 20-21-14] from the cylinder head.

P-48071

Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-12].

T190 Bobcat Loader


20-21-6 Service Manual
CYLINDER (TILT) (CONT'D) Assembly

Disassembly (Cont'd) Use the following tools to assemble the cylinder:

Figure 20-21-15 MEL1396 - Seal Installation Tool


MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench

1 Figure 20-21-17

P-48040

Remove the wiper seal (Item 1) [Figure 20-21-15] from


the cylinder head.
P7424
Figure 20-21-16

Wash the cylinder parts in solvent and air dry them.

Inspect the cylinder parts for nicks, scratches or other


damage. Replace any damaged parts.

Always install new O-rings and seals during assembly.


1
Lubricate all O-rings and seals with hydraulic oil during
installation.

Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-17].

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


on the piston.
Remove the rod seal (Item 1) [Figure 20-21-16] from the
cylinder head.

T190 Bobcat Loader


20-21-7 Service Manual
CYLINDER (TILT) (CONT'D) Figure 20-21-20

Assembly (Cont'd)

Figure 20-21-18

P7425

Install the rod seal in the head [Figure 20-21-20].


P-48073
Figure 20-21-21

Install the O-ring (Item 1) and seal (Item 2) [Figure 20-


21-18] on the cylinder piston.
2
Figure 20-21-19

P-48041 P-48042

Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-21-
P-48043 P7427 21].

Install the rod seal on the rod seal tool [Figure 20-21-19].

NOTE: During installation the spring side of the seal


(Item 1) [Figure 20-21-19] must be installed
toward the inside of the cylinder.

Rotate the handles to collapse the rod seal [Figure 20-


21-19].

T190 Bobcat Loader


20-21-8 Service Manual
CYLINDER (TILT) (CONT'D) Figure 20-21-24

Assembly (Cont'd)

Figure 20-21-22
1

1
2

P-48070

Put the base end of the hydraulic cylinder in a vise.


P-48071
Tighten the head (Item 1) [Figure 20-21-24] using a
spanner wrench.
NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.

Install the head (Item 1), piston (Item 2) and nut (Item 3)
[Figure 20-21-22].

Tighten the nut (Item 3) [Figure 20-21-22] to 100 ft.-lbs.


(136 Nm) torque.

Figure 20-21-23

P-48088 P-48089

Mark the end of the shaft and nut. Tighten the nut an
additional 135 degrees or 2-1/4 flats [Figure 20-21-23].

T190 Bobcat Loader


20-21-9 Service Manual
CYLINDER (POWER BOB-TACH) Figure 20-22-2

Checking

WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
1

P16330

WARNING Disconnect the hose (Item 1) [Figure 20-22-2] from the


power Bob-Tach cylinder base end port.
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
Figure 20-22-3
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496

2
Figure 20-22-1

1 P16332

Install a plug in the hose (Item 1) [Figure 20-22-3] and


tighten.

Engage the parking brake. Lower the seat bar. Start the
engine.
N-21401
Push and hold the BOB-TACH "WEDGES UP" Switch
(Front Accessory Panel).
Tilt the Bob-Tach forward, so it is parallel to the floor
[Figure 20-22-1]. If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-22-3], remove the Power Bob-Tach
cylinder for repair.

T190 Bobcat Loader


20-22-1 Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D)

Removal And Installation

Figure 20-22-4

1 1

N-21401

Disconnect the hoses from the cylinder fittings (Item 1 &


2) [Figure 20-22-4].

Install plugs and cap on fittings.

NOTE: Connect the hose with the 45° end (Item 1)


[Figure 20-22-4] to the base end fitting on the
cylinder.

Figure 20-22-5

N-21400

Remove the bolts (Item 1) [Figure 20-22-5].

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


Nm) torque.

Remove the washers and cylinder from the lever pivots.

T190 Bobcat Loader


20-22-2 Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D)

Identification

1. Cylinder 8. Ring
2. Nut 9. O-ring
3. Piston 10. Head
4. O-ring 11. Seal
5. Ring 12. Seal
6. Spacer 13. Rod
7. O-ring

2
3
4
5
6

7
8 9
10
11
12

13

B-16276

T190 Bobcat Loader


20-22-3 Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D) Figure 20-22-8

Disassembly
3
2
Use the following tools to disassemble the cylinder:
1
MEL1074 - O-ring Seal Hook
Spanner Wrench

Hold the hydraulic cylinder over a drain pan and move


the rod in and out slowly to remove the fluid from the
cylinder.

Figure 20-22-6

P16295

Piston: Remove the O-ring (Item 1), and seal (Item 2)


from the piston (Item 3) [Figure 20-22-8].

Figure 20-22-9

3 5
4

P16293

2
1
Put the base end of the cylinder in a vise.

Use a spanner wrench to loosen the head [Figure 20-22-


6].

Figure 20-22-7
N-20611

3 2 Remove the wiper seal (Item 1), and rod seal (Item 2),
1 the back up washer (Item 3) the thin O-ring (Item 4) and
the thick O-ring (Item 5) from the head [Figure 20-22-9].

P16294

Remove the head and rod assembly from the cylinder


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

Remove the nut (Item 1), piston (Item 2) and head (Item
3) from the rod [Figure 20-22-7].

T190 Bobcat Loader


20-22-4 Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D) Figure 20-22-11

Assembly
3
Use the following tools to assembly the cylinder: 2 1

MEL1396 - Seal Installation Tool


MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
4
Wash the cylinder parts in solvent and air dry them.

Inspect the cylinder parts for nicks, scratches or other


damage. Replace any damaged parts.
P16295
Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during Piston: Install the O-ring (Item 1) and seal (Item 2) on the
installation. piston (Item 3) [Figure 20-22-11].

Figure 20-22-10 NOTE: The piston center hole (Item 4) [Figure 20-22-
11] has a bevel on one end. The bevel goes
toward the rod.

Figure 20-22-12

P7424

Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-10]. N-20612

Allow the seal to stretch for 30 seconds before installing it


on the piston. Install the rod seal on the rod seal tool [Figure 20-22-12].

NOTE: During installation the O-ring side of the seal


must be toward the inside of the cylinder.

T190 Bobcat Loader


20-22-5 Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D) Figure 20-22-15

Assembly (Cont’d)

Figure 20-22-13

2
3

P7422

Install the thin O-ring (Item 1) [Figure 20-22-15].


N-20613
Install the back-up washer (Item 2) and thick O-ring (Item
3) into the groove on the head [Figure 20-22-15].
Rotate the handles to collapse the rod seal [Figure 20-
22-13]. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the seal kit.
Figure 20-22-14
Figure 20-22-16

1 3
2 4

P7425
P16294

Install the rod seal in the head [Figure 20-22-14].


Install the head (Item 1), and spacer (Item 2) [Figure 20-
Install the wiper seal with the wiper toward the outside of 22-16].
the head.
Install the piston (Item 3) [Figure 20-22-16].

Grease the piston where the nut contacts the piston. do


not get grease on the threads. Install the new nut (Item 4)
[Figure 20-22-16].

Tighten the nut to 90 ft.-lbs. (122 Nm) torque.

T190 Bobcat Loader


20-22-6 Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D)

Assembly (Cont’d)

Figure 20-22-17

P16293

Put the base end of the hydraulic cylinder in a vise.

Tighten the head using a spanner wrench [Figure 20-22-


17].

T190 Bobcat Loader


20-22-7 Service Manual
MAIN RELIEF VALVE Figure 20-30-1

Checking

2
IMPORTANT 1

The hydraulic tester must be in the fully open


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

WARNING P-34480

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

WARNING Figure 20-30-2

Put jackstands under the front axles and rear corners


of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

The tools listed will be needed to do the following


procedure:
1
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit

Turn the key switch to the OFF position. To release the N-18409
hydraulic pressure at the front auxiliary quick couplers
push the couplers into the coupler block and hold for
three seconds. Start the engine and run at low idle.

Lift and block the loader. (See Procedure on Page 10-10- • Press the AUXILIARY HYDRAULICS Button (Item 1)
1.) [Figure 20-30-2] twice and the light beside Maximum
Flow comes on.

T190 Bobcat Loader


20-30-1 Service Manual
MAIN RELIEF VALVE (CONT’D) Adjustment

Checking (Cont’d) Figure 20-30-4

Figure 20-30-3

Right
Steering
Lever O-ring
Control

Back-up
B-6764

1
P-31833
If the pressure is not correct, adjust the main relief valve.
Remove the end cap (Item 1) [Figure 20-30-4] if
• Push the front switch (Item 1) [Figure 20-30-3] to give equipped.
the front quick couplers a constant flow of fluid.
Turn the adjusting screw in or out until the pressure is
• To release from continuous operation, press the front correct.
switch (Item 1) [Figure 20-30-3] a second time.
NOTE: If the correct pressure can not be reached,
Watch the flow meter on the hydraulic tester to make replace the main relief valve. Check the
sure the flow is correct. Increase the engine speed to full pressure setting of the new relief valve.
RPM.

Refer to Specifications, (Contents Page, SPEC-01) for


both flow and pressure specifications of the hydraulic
system.
Check the free flow specification.

Turn the restrictor control, on the tester, until the main


relief valve opens. Check the relief pressure.

If the relief pressure is not correct, stop the engine and


adjust the main relief valve.

T190 Bobcat Loader


20-30-2 Service Manual
MAIN RELIEF VALVE (CONT’D)

Removal and Installation

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

Figure 20-30-5

1
P-24710

P-48430

Clean the area around the control valve. Loosen and


remove the main relief valve (Item 1) [Figure 20-30-5].

Remove the O-rings and back-up washers [Figure 20-


30-4].

Clean the main relief valve in clean solvent. Use air


pressure to dry the valve.

Install new O-rings and back-up washers. Install the main


relief valve (Item 1) [Figure 20-30-5] and tighten. Check
the pressure again. (See Checking on Page 20-30-1.)

Installation: Tighten the main relief valve to 35-40 ft.-lbs.


(47-54 Nm) torque.

T190 Bobcat Loader


20-30-3 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL)

Identification IMPORTANT
Figure 20-40-1 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Lift and block the loader. (See Procedure on Page 10-10-


1.)

Raise the lift arms and install an approved lift arm support
device (See Installing Lift Arm Support Device on Page
10-20-1.)
1
Raise the operator cab. (See Raising The Operator Cab
N-18695
on Page 10-30-1.)

The hydraulic control valve (2 piece casting) (foot control) Clean the area around the control valve.
has a removable BICS™ section (Item 1) [Figure 20-40-
1]. Drain the hydraulic reservoir. (See Replacing Hydraulic
Fluid on Page 10-120-2.)
The BICS™ section and main control valve are in two
seperate castings. Remove the control panel. (See Removal and Installation
on Page 50-100-1.)
For identification of the hydraulic control valve (1 piece
casting) (foot control), (See Identification on Page 20-42- Figure 20-40-2
1.)

Removal And Installation

P-48286

WARNING Mark all tubelines and hoses for correct installation.


Never work on a machine with the lift arms up unless
The fixed end main valve hose assembly (Item 1)
the lift arms are secured by an approved lift arm
[Figure 20-40-2] is connected to a fixed end fitting on the
support device. Failure to use an approved lift arm
control valve. The hose is routed to the back upright
support device can allow the lift arms or attachment
where the hose is connected to a tee fitting that feeds
to fall and cause injury or death.
W-2059-0598 the base end of both lift cylinders. The hose must be
removed at the back tee fitting, located in the right side
upright.

T190 Bobcat Loader


20-40-1 Service Manual
NOTE: Remember the hose routing for ease of HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
control valve installation. (FOOT CONTROL) (CONT’D)

Removal and Installation (Cont’d)

Figure 20-40-3

P-31999

Remove the tie - strap (Item 1) [Figure 20-40-3] from the


fixed end main valve hose.

Figure 20-40-4

4
2

P-48288

Mark and disconnect the four electric solenoid


connectors for correct installation (Item 1) [Figure 20-40-
4].
Remove the outlet tubeline (Item 2) [Figure 20-40-4]
from the control valve to the hydraulic oil cooler.

Disconnect and cap the brake block hose (Item 3)


[Figure 20-40-4] from the control valve.

Remove the wire harness clamp bolt (Item 4) [Figure 20-


40-4].

T190 Bobcat Loader


20-40-2 Service Manual
Figure 20-40-5 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)
1
Removal And Installation (Cont'd)

Figure 20-40-7
2

4 3
1

P-48289

Mark all tubelines and hoses for correct installation.

Disconnect and cap the tubeline (Item 1) [Figure 20-40- P-48290


5] from the lift lock valve.

Disconnect and remove the BICS™ valve drain tubeline Remove the two lift arm by-pass valve mounting bolts
(Item 2) [Figure 20-40-5] from the control valve. (Item 1) [Figure 20-40-7]

Disconnect and remove the hose (Item 3) [Figure 20-40- Figure 20-40-8
5] from the lift arm by-pass valve to the drain on the
control valve.

Disconnect the drive motor case drain hose (Item 4)


[Figure 20-40-5].
1
Figure 20-40-6

P-48291A

1 Remove the wire harness clamp bolt (Item 1) [Figure 20-


40-8].

Remove the control pedal crossbar linkage and tilt


linkage. (See Linkage Removal And Installation on Page
P-48287
50-100-5.)

Remove the connector pins (Item 1) [Figure 20-40-6] .

T190 Bobcat Loader


20-40-3 Service Manual
Figure 20-40-9 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Removal And Installation (Cont'd)


1 1
Figure 20-40-11

1
2
P-48292A

Remove and cap both tubelines (Item 1) [Figure 20-40-


9] from the auxiliary section of the control valve.
P-48294
Disconnect and cap the hose (Item 2) [Figure 20-40-9]
from the hydraulic reservoir.
Disconnect and cap the pump hose (Item 1) [Figure 20-
Figure 20-40-10 40-11] at the bottom of the control valve.

Mark and disconnect the BICS™ electric solenoid


3 connector (Item 2) [Figure 20-40-11].

Figure 20-40-12

2
5
1
4

P-48883

Remove the tilt tubeline (Item 1) [Figure 20-40-10] from


the bucket positioning valve and the control valve (if so
equipped).. P-48295

Disconnect the lift tubeline (Item 2) [Figure 20-40-10].


Connect a hoist to the control valve (Item 1) [Figure 20-
Disconnect the tilt tubeline (Item 3) [Figure 20-40-10]. 40-12].

Remove the tilt tubeline (Item 4) [Figure 20-40-10] from


the bucket positioning valve and the control valve (If
equipped with bucket positioning valve).

Disconnect the tilt tubeline (Item 5) [Figure 20-40-10].

T190 Bobcat Loader


20-40-4 Service Manual
Figure 20-40-13 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

BICS™ Valve Removal And Installation


1 Figure 20-40-14

1 P-26062

1 1

1 1

P-26095 P-26061
1
1
Remove the two mounting bolts (Item 1) [Figure 20-40-
13] fastening the control valve and bracket to the side of
the loader. N-18679

Remove the control valve from the loader [Figure 20-40-


13]. Remove the control valve. (See Removal And Installation
on Page 20-40-1.)
Reverse procedure for installation.
To remove the BICS™ from the control valve loosen and
remove the six mounting bolts (Item 1) [Figure 20-40-
14].

Figure 20-40-15

N-18695

Remove the BICS™ valve assembly from the top of the


control valve [Figure 20-40-15].

T190 Bobcat Loader


20-40-5 Service Manual
Figure 20-40-16 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

BICS™ Valve Removal And Installation (Cont’d)

STEP TORQUE SEQUENCE


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

*Torque must be 190-210 in.-lbs. (21,5-23,7 Nm) for


N-18697 every bolt or repeat step 3.

BICS™ Valve, Lift Arm By-Pass Orifice Disassembly


Remove the four large O-rings (Item 1) [Figure 20-40- And Assembly
16] and the small O-ring (Item 2) [Figure 20-40-16] from
the top of the control valve. Figure 20-40-18
Install the four large O-rings (Item 1) [Figure 20-40-16]
and the small O-ring (Item 2) [Figure 20-40-16] on the
top of the control valve.

Figure 20-40-17

6
3
1

1 2
N-18686

5
4 Remove the fitting (Item 1) [Figure 20-40-18] from the
valve.

N-18679

Install the six mounting bolts [Figure 20-40-17].

The chart below lists the correct torque specifications


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

T190 Bobcat Loader


20-40-6 Service Manual
Figure 20-40-19 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

BICS™ Valve, Check Valve Disassembly And


Assembly

Figure 20-40-21

N-18687

1
Figure 20-40-20

N-18683

Remove the check valve (Item 1) [Figure 20-40-21].

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


torque.

Figure 20-40-22
1

N-18685
3

Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-40-19] & [Figure 20-40-
20]. 2
1
Orifice size is 0.078 inch.

Reverse the removal procedure to install the lift arm by-


pass orifice.
N-18684

Remove and install with new O-rings (Item 1) and back-


up ring (Item 2) [Figure 20-40-22].

Check valve (Item 3) [Figure 20-40-22] has a rating of 5-


10 PSI.

T190 Bobcat Loader


20-40-7 Service Manual
Figure 20-40-23 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

BICS™ Valve Lock Valve Disassembly And Assembly

1 Figure 20-40-24

1 1

P-8956

Clean and inspect the screen (Item 1) [Figure 20-40-23]


on the end of the valve.
N-18682
Reverse the removal procedure to install the BICS™
check valve.
Figure 20-40-25

N-18688

T190 Bobcat Loader


20-40-8 Service Manual
Figure 20-40-26 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

BICS™ Valve Solenoid Disassembly And Assembly

Figure 20-40-28

N-18689

Remove the lock valves (Item 1) [Figure 20-40-24],


[Figure 20-40-25] & [Figure 20-40-26] from the BICS™
valve. N-18691

Installation: Tighten the lock valves to 25 ft.-lbs. (34 Nm)


torque. Remove the mounting nut (Item 1) [Figure 20-40-28]
from the solenoid cartridge.
Figure 20-40-27
Installation: Tighten the mounting nut to 53 in.-lbs. (6
Nm) torque.
1
Remove the solenoid (Item 2) [Figure 20-40-28].

NOTE: The solenoid resistance valve is (8-10 ohms).

1 Figure 20-40-29

1
2
1
2
2
N-18690

Remove the O-rings (Item 1) [Figure 20-40-27] and


back-up rings (Item 2) [Figure 20-40-27] from both the tilt
and lift lock valves.

Install new O-rings (Item 1) [Figure 20-40-27] and back-


up rings (Item 2) [Figure 20-40-27] on the tilt and lift lock N-18693A
valves.

Reverse the removal procedure to install the lock valve. Remove the O-rings (Item 1) [Figure 20-40-29] from
both ends of the solenoid.

T190 Bobcat Loader


20-40-9 Service Manual
Figure 20-40-30 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

BICS™ Valve Solenoid Disassembly And Assembly


1 (Cont’d)

Figure 20-40-31

3
2

N-18692

Remove the solenoid cartridge (Item 1) [Figure 20-40-


30]. 1

Installation: Tighten the cartridge to 20 ft.-lbs. (27 Nm) N-18694


torque.

Remove the O-rings (Item 1) [Figure 20-40-31] and


back-up rings (Item 2) [Figure 20-40-31] from the
cartridge.

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear and replace any showing


excessive wear.

NOTE: The screen (Item 3) [Figure 20-40-31] may be


cleaned with solvent. If it is torn or worn it
needs to be replaced.

Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.

Install new O-rings (Item 1) [Figure 20-40-29] & [Figure


20-40-31] and new back-up rings (Item 2) [Figure 20-40-
31] on the solenoid cartridge.

T190 Bobcat Loader


20-40-10 Service Manual
BICS™ Valve Solenoid Testing HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)
Figure 20-40-32
Identification Chart

ITEM T190 LOADER


A1 Lift Cylinder Base End/Restrictor
A2 Tilt Cylinder Base End
A3 Auxiliary Hydraulics
B1 Lift Cylinder Rod End
B2 Tilt Cylinder Rod End
B3 Auxiliary Hydraulics
C1 Load Check Valve/Lift Function
C2 Load Check Valve/Tilt Function
C3 Orificed Load Check Valve/Auxiliary Function
P9175
C4 Outlet Fluid Flow
D1 Lift Spool Detent
D2 Tilt Spool Centering Spring
Use an Ohm meter to measure coil resistance [Figure
D3 Auxiliary Spool/Centering Springs
20-40-32].
E1 Port Relief Valve – 3500 PSI
Coil wires do not have polarity. E2 Anti–Cavitation/Port Relief Valve – 3500 PSI
F1 Anti-Cavitation Valve
Correct resistance for the auxiliary, lift and tilt lock coils F2 Port Relief Valve – 3500 PSI
are 7-10 ohms G1 LIft Spool End
G2 Tilt Spool End
The other coils (BICS™, diverter, select valve) are 5-8
ohms. G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional) – 3100 PSI
H3 Auxiliary Electric Solenoid
MR Main Relief Valve – 3300 PSI

Figure 20-40-33

H2 H1
H3

C4
A3 D3
B3
G3
C3
G2 B2 A2 D2
E2
F2 C2
G1 B1 A1 E1 D1
F1 C1
MR

TS-1918

T190 Bobcat Loader


20-40-11 Service Manual
Load Check Valve HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)
Figure 20-40-34
Load Check Valve (Cont’d)

Figure 20-40-35

1 1

1
1

2 1

N-18697

Remove the BICS™ valve assembly from the control N-18698


valve. (See Removal And Installation on Page 20-40-1.)

Remove the four large O-rings (Item 1) and small O-ring Mark each valve section, spool and related parts so that
(Item 2) [Figure 20-40-34]. Always replace these O-rings they will be returned to its original valve section during
before installing the BICS™ valve assembly. assembly.

Use bolts to fasten the control valve to a work bench for


easier disassembly and assembly procedures.

WARNING Loosen the load check valve plugs (Item 1) [Figure 20-
40-35].
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Installation: Always use new O-ring. Tighten the plug to
parts clean. Always use caps and plugs on hoses, 35-40 ft.-lbs. (47-54 Nm) torque.
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Figure 20-40-36
I-2003-0888

3
2 N-18699

Remove the load check plugs (Item 1) [Figure 20-40-36].

Remove the spring (Item 2) and poppet (Item 3) [Figure


20-40-36].

T190 Bobcat Loader


20-40-12 Service Manual
Figure 20-40-37 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)
1 Main Relief Valve (Cont’d)

Figure 20-40-39

N-18700

The auxiliary section (Item 1) [Figure 20-40-37] uses an 1


orifice load check poppet (Item 2) [Figure 20-40-37].
N-19031
NOTE: For correct port locations and valve
component values. (See BICS™ Valve
Removal And Installation on Page 20-40-5.) Remove the main relief valve (Item 1) [Figure 20-40-39].

Main Relief Valve Figure 20-40-40

2 3
Figure 20-40-38 4 5

1. Relief Valve
2. O-ring
3. Sleeve
4. Glide Ring
5. O-ring
1
CD-15092

N-18923
Remove the O-rings, sleeve, and glide ring from the main
relief valve [Figure 20-40-40].
Loosen the main relief valve (Item 1) [Figure 20-40-38].
Installation: Always use new O-rings. sleeve, and glide
ring. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.

T190 Bobcat Loader


20-40-13 Service Manual
Port Relief Valve HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)
Figure 20-40-41
Port Relief Valve (Cont’d)

Figure 20-40-43

N-18976

Figure 20-40-42 N-18977

Remove the port relief valve (Item 1) [Figure 20-40-43].

Figure 20-40-44
1
4
3

2
1

N-18923 1. O-ring
2. Backup Washer
3. O-ring
Loosen the port relief valve (Item 1) [Figure 20-40-41] & 4. Relief Valve
[Figure 20-40-42] (Port E1 or F2).
N-18844
Installation: Always use new O-rings and back-up
washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
Remove the O-rings and back-up washer from the port
relief valve [Figure 20-40-44].

T190 Bobcat Loader


20-40-14 Service Manual
Anti-Cavitation Valve/Port Relief Valve HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)
Figure 20-40-45
Anti-Cavitation Valve/Port Relief Valve (Cont’d)

Figure 20-40-47

1
1

N-18976

Loosen the anti-cavitation valve (Item 1) [Figure 20-40- N-18843


45].

Installation: Always use new O-rings and back-up Remove the O-rings (Item 1) [Figure 20-40-47] from the
washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque. anti-cavitation/port relief valve.

Figure 20-40-46 Anti-Cavitation Valve

Figure 20-40-48

N-18978

N-18923
Remove the anti-cavitation/port relief valve (Item 1)
[Figure 20-40-46] from the control valve for the tilt
section.

T190 Bobcat Loader


20-40-15 Service Manual
Figure 20-40-49 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Rubber Boot

Figure 20-40-51
2

N-19032

1
Remove the lift lock solenoid (Item 1) [Figure 20-40-48]
& [Figure 20-40-49].
N-18923
Remove the anti-cavitation valve (Item 2) [Figure 20-40-
48] & [Figure 20-40-49] from the control valve for the lift
section. Remove the two screws (Item 1) [Figure 20-40-51] on
the rubber boot retainer.
Figure 20-40-50
Installation: Tighten the screws to 90-100 in.-lbs. (10,2-
2 11,3 Nm) torque.
1 3 4

Figure 20-40-52

E-01509 1

1. Anti-Cavitation Valve
2. O-ring
3. Backup Washer
4. O-ring

N-18839
1 2

Remove the O-rings and back-up washer from the anti-


cavitation valve [Figure 20-40-50]. N-18924

Remove the rubber boot (Item 1) [Figure 20-40-52] and


retainer (Item 2) [Figure 20-40-52].

T190 Bobcat Loader


20-40-16 Service Manual
Lift And Tilt Lock Block HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)
Figure 20-40-53
Lift And Tilt Lock Block (Cont’d)

Figure 20-40-55

N-18923

Figure 20-40-54 N-18926

Remove the block [Figure 20-40-55].


1
NOTE: The lock block must be clean and oil free. (Oil
can cause the solenoids not to function
properly.)

Lift Spool and Detent

2 Figure 20-40-56

2 1

N-18925

Removal And Installation

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


[Figure 20-40-54] from the lock block.

Remove the rubber boot (Item 2) [Figure 20-40-53] &


[Figure 20-40-54]. (See Rubber Boot on Page 20-40-
16.) 1
N-18923

The tool listed will be needed to do the following


procedure:

MEL1278 - Detent Tool


MEL1285 - Detent Spring Tool

Remove the lift and tilt lock block (Item 1) [Figure 20-40-
56] from the control valve. (See Lift And Tilt Lock Block
on Page 20-40-17.)

T190 Bobcat Loader


20-40-17 Service Manual
Figure 20-40-57 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent (Cont’d)

Figure 20-40-59

2
1

N-18927

Remove the spacer (Item 1) [Figure 20-40-57] and O- 2


ring (Item 2) [Figure 20-40-57] from the lift spool.
N-18971
Figure 20-40-58

Use a screwdriver to remove the snap ring (Item 1)


[Figure 20-40-59].

Remove the washer (Item 2) [Figure 20-40-59].

Figure 20-40-60

N-18976 1

Remove the end cap (Item 1) [Figure 20-40-58].


2

1 N-18972

Remove the screws (Item 1) [Figure 20-40-60] from the


detent bonnet.

Remove the detent bonnet (Item 2) [Figure 20-40-60].

T190 Bobcat Loader


20-40-18 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)
WARNING Lift Spool and Detent (Cont'd)

The detent assembly has small springs and balls. Do Figure 20-40-63
not lose these parts during disassembly and
assembly.

Figure 20-40-61

N-18975

Remove the spool assembly and seal (Item 1) [Figure


20-40-63] from the control valve.
N-18973
Figure 20-40-64

Put a rag around the detent assembly [Figure 20-40-61].


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

Figure 20-40-62

3 2
1
N-18930

Remove the spool seal (Item 1) [Figure 20-40-64] from


the linkage end of the valve.
2

N-18974

Remove the detent sleeve (Item 1) [Figure 20-40-62],


detent balls (Item 2) [Figure 20-40-62] and spring (Item
3) [Figure 20-40-62].

T190 Bobcat Loader


20-40-19 Service Manual
Figure 20-40-65 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent (Cont'd)

Figure 20-40-67

P-8988

Clamp the linkage end of the spool in a vise [Figure 20- 1


2
40-65].
N-18916
NOTE: Protect spool before clamping in vise.

Figure 20-40-66 Put a rag around the detent assembly [Figure 20-40-67].
This will prevent the detent balls and spring from being
2 lost when the detent adapter is removed.

Remove the detent adapter with an allan wrench.

1 Remove the back-up washer (Item 1) [Figure 20-40-67]


3 and spool seal (Item 2) [Figure 20-40-67].

Figure 20-40-68

N-18915

Install the spring tool (Item 1) [Figure 20-40-66] over the


centering spring.

NOTE: Be careful when removing the detent adapter


(Item 2) [Figure 20-40-66] from the centering
spring, as it is under spring pressure.
N-19004
NOTE: The centering spring (Item 3) [Figure 20-40-66]
is white on all 700 series loaders.
Remove the detent adapter (Item 1) [Figure 20-40-68]
from the spring assembly.

T190 Bobcat Loader


20-40-20 Service Manual
Figure 20-40-69 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)
1 Lift Spool and Detent (Cont'd)

Figure 20-40-71

N-19009

Remove spring tool (Item 1) [Figure 20-40-69] from the


spring assembly.
N-18918
Figure 20-40-70

Remove the stud from the end of the spool [Figure 20-
1 40-71].
2
3 Figure 20-40-72

N-18919A
1

Inspect the adapter (Item 1) [Figure 20-40-70], collar


(Item 2) [Figure 20-40-70], spring (Item 3) [Figure 20-
40-70], and washer (Item 4) [Figure 20-40-70]. N-18920

Removal of the plastic plug:

Make a center point in the plug using a 1/16 inch drill.

Drill a hole all the way through the plug using a 7/64 inch
tap drill

Turn a 6-32 tap (Item 1) [Figure 20-40-72] into the plug.


Pull the tap and plug out of the spool. Be careful, do not
break the tap.

Clean all the debris from inside the spool bore.

NOTE: DO NOT USE LOCTITE ON THE STUD


THREADS.

T190 Bobcat Loader


20-40-21 Service Manual
Figure 20-40-73 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent (Cont'd)

2 Figure 20-40-75
1
O-ring

N-18961 Plastic
Plug
0.60 inch
(15,2 mm)
Install the O-ring (Item 1) [Figure 20-40-73] over the
nipple on the plastic plug (Item 2) [Figure 20-40-73].
B-14712
Figure 20-40-74

Install the stud and tighten until the other end of the stud
is out about 0.600 inch (15,2 mm) from the spool [Figure
20-40-75].

Figure 20-40-76

N-18963

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

N-18967

Clamp the collar (Item 1) [Figure 20-40-76] in a vice.

T190 Bobcat Loader


20-40-22 Service Manual
Figure 20-40-77 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent (Cont'd)

2 Figure 20-40-79

1 1
3
2

N-18958

Apply grease on all the detent component surfaces


before assembly [Figure 20-40-77].
N-19004
Install the spring (Item 1) [Figure 20-40-77] and detent
balls (Item 2) [Figure 20-40-77] into the adapter (Item 3)
[Figure 20-40-77] and compress with the detent pliers Install the spring tool (Item 1) [Figure 20-40-79] over the
(Item 1) [Figure 20-40-78]. washer, spring, collar and detent adapter.

Figure 20-40-78 Figure 20-40-80

N-18917
N-18968

Install the detent adapter to the collar [Figure 20-40-78]. Install the spool seal (Item 1) [Figure 20-40-80] and
back-up washer (Item 2) [Figure 20-40-80].
NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.

T190 Bobcat Loader


20-40-23 Service Manual
Figure 20-40-81 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent (Cont'd)

Figure 20-40-83

N-19005

Install the spring assembly to the lift spool hand tight


[Figure 20-40-81].
N-19007
Remove the spring tool.

Check the alignment of the detent adapter and the Hold the detent balls in place with the detent pliers
washer. [Figure 20-40-83].

Tighten the adapter to 90-100 in.-lbs. (10,2-11,3 Nm). Figure 20-40-84

NOTE: The adapter must fit in the center of the


washer (Item 1) [Figure 20-40-81].

Figure 20-40-82

N-19008

Install the detent sleeve (Item 1) [Figure 20-40-84] to the


detent adapter.
CD-15051

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

T190 Bobcat Loader


20-40-24 Service Manual
Figure 20-40-85 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent (Cont'd)

Figure 20-40-87

2
N-18972 1

Install the lift spool assembly in the spool bore [Figure


20-40-85].
N-18976
Install the detent bonnet (Item 1) [Figure 20-40-85].

Install the mounting screws (Item 2) [Figure 20-40-85]. Install the end cap (Item 1) [Figure 20-40-87].

Installation: Tighten the screws to 90-100 in.-lbs. (10,2- Figure 20-40-88


11,3 Nm) torque.

Figure 20-40-86

1
2

N-18930

1
Install the spool seal (Item 1) [Figure 20-40-88] on the
N-18971
linkage end of the valve.

Install the washer (Item 1) [Figure 20-40-86] and snap


ring (Item 2) [Figure 20-40-86].

T190 Bobcat Loader


20-40-25 Service Manual
Figure 20-40-89 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Tilt Spool Removal And Installation

Figure 20-40-91

1 2

N-18927

Install the spacer (Item 1) [Figure 20-40-89] and O-ring 1


(Item 2) [Figure 20-40-89] on the linkage end of the lift
spool. N-18923

Figure 20-40-90
Remove the lift and tilt lock block (Item 1) [Figure 20-40-
91] from the control valve. (See Lift And Tilt Lock Block
on Page 20-40-17.)

Figure 20-40-92

2
1

N-18923

Install the lift and tilt lock block (Item 1) [Figure 20-40-
90]. (See Lift And Tilt Lock Block on Page 20-40-17.)
N-18928

Remove the spacer (Item 1) [Figure 20-40-92] and O-


ring (Item 2) [Figure 20-40-92] from the tilt spool.

T190 Bobcat Loader


20-40-26 Service Manual
Figure 20-40-93 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Tilt Spool Removal And Installation (Cont'd)

Figure 20-40-95

1 1

N-18686

Remove the screws (Item 1) [Figure 20-40-93] from the


end cap.
N-18942
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
Put the linkage end of the spool in the vice [Figure 20-
Figure 20-40-94 40-95].

Install the spool tool (Item 1) [Figure 20-40-95] over the


centering spring.

Figure 20-40-96

N-18816

Remove the spool, centering spring, back-up washer and


spool seal [Figure 20-40-94].
N-19014
Assembly: Always use a new spool seal.

Remove the bolt (Item 1) [Figure 20-40-96] holding the


centering spring to the spool.

Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3


Nm) torque.

Remove spring tool from the spring assembly.

T190 Bobcat Loader


20-40-27 Service Manual
Figure 20-40-97 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Auxiliary Spool Removal And Installation


2 1
Figure 20-40-99
3

N-18944A 1

Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-40-97].
N-18976
Figure 20-40-98

Remove the screws (Item 1) [Figure 20-40-99] from the


2 end cap (both sides).
1
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.

Figure 20-40-100

1
1

N-18930 N-18943

Remove the spool seal(s) (Item 1) and the back-up


washer (Item 2) [Figure 20-40-98].

Assembly: Always use a new spool seal.

N-18990

Remove the end cap, O-ring, springs and center spring


retainer (both sides) [Figure 20-40-100].

Note: If the centering spring retainer (Item 1) [Figure


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

Assembly: Always use a new spool seal.

T190 Bobcat Loader


20-40-28 Service Manual
Figure 20-40-101 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Auxiliary Electric Solenoid Disassembly


1
Figure 20-40-102

N-18989
1

Remove the spool (Item 1) [Figure 20-40-101]. 1

Assembly: Put grease on all the centering spring N-18822


component parts.

Remove the nut (Item 1) [Figure 20-40-102] from both


solenoids.

Installation: Tighten the nut to 8-12 ft.-lbs. (11-16 Nm)


torque.

Figure 20-40-103

2
1

N-18823

Remove the end plate (Item 1) and housing (Item 2)


[Figure 20-40-103].

T190 Bobcat Loader


20-40-29 Service Manual
Figure 20-40-104 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Port-Auxiliary Section Disassembly

Figure 20-40-106

2
3
1

N-18992
1

Remove the coil (Item 1) and end plate (Item 2) [Figure


20-40-104].
N-18993
Remove the solenoid valve (Item 3) [Figure 20-40-104].

Installation: Tighten valve to 8-12 ft.-lbs. (11-16 Nm) Remove the plug (Item 1) [Figure 20-40-106] or optional
torque. port relief valve from the control valve.

Figure 20-40-105 NOTE: Optional port relief (Item 1) [Figure 20-40-106]


is set at 3500 PSI.

Figure 20-40-107
Plug
1

1
N-18795
1

Remove the O-rings (Item 1) [Figure 20-40-105] from N-18800


the solenoid valves.

T190 Bobcat Loader


20-40-30 Service Manual
Figure 20-40-108

Port Relief (Optional)

1 2

N-18843

Remove the O-rings (Item 1) [Figure 20-40-107] &


[Figure 20-40-108] and back-up ring (Item 2) [Figure 20-
40-107] & [Figure 20-40-108] from the plug.

Cleaning And Inspection

Clean all components with clean solvent and dry with


compressed air.

Check the spools for wear or scratches.

Check that the spools are not loose in their bore.

Check that the centering springs are not broken.

Check that the load check valve seats are not worn.

Check the load check poppets for damage.

Check the rubber boots and retainers.

Replace the parts as needed.

Use new O-rings and back-up rings.

Apply oil to all new O-rings and back-up rings before


installation.

T190 Bobcat Loader


20-40-31 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS)

Identification IMPORTANT
Figure 20-41-1 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Lift and block the loader. (See Procedure Page 10-10-1.)

Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device Page 10-
20-1.)
1
Raise the operator cab. (See Raising The Operator Cab
Page 10-30-1.)
N-18695

Clean the area around the control valve.


The hydraulic control valve (2 piece casting) (Advance
Control System) (ACS) has a removable BICS™ section Drain the hydraulic reservoir. (See Replacing Hydraulic
(Item 1) [Figure 20-41-1]. Fluid Page 10-120-2.)

The BICS™ section and main control valve are in two Remove the control panel. ((See Removal and
seperate castings. Installation Page 50-100-1.)

For identification of the hydraulic control valve (1 piece Figure 20-41-2


casting) (Advanced Control System) (ACS),(See
Identification Page 20-43-1.)
1
Removal and Installation

P-31998

WARNING Mark all tubelines and hoses for correct installation.

The fixed end main valve hose assembly (Item 1) [Figure


Never work on a machine with the lift arms up unless
20-41-2] is connected to a fixed end fitting on the control
the lift arms are secured by an approved lift arm
valve. The hose is routed to the back upright where the
support device. Failure to use an approved lift arm
hose is connected to a tee fitting that feeds the base end
support device can allow the lift arms or attachment
of both lift cylinders. The hose must be removed at the
to fall and cause injury or death.
W-2059-0598 back tee fitting, located in the right side upright.

NOTE: Remember the hose routing for ease of


control valve installation.

T190 Bobcat Loader


20-41-1 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-5
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Removal and Installation (Cont’d)


4
Figure 20-41-3

2
3
1
P-48894

Disconnect the tubeline (Item 1) [Figure 20-41-5] from


the lift arm by-pass valve.
P-31999
Disconnect the drain hose (Item 2) [Figure 20-41-5] from
the control valve.
Remove the tie - strap (Item 1) [Figure 20-41-3] from the
fixed end main valve hose. Disconnect the motor case drain hose (Item 3) [Figure
20-41-5] from the lift arm by-pass valve.
Figure 20-41-4
Remove the bolts (Item 4) [Figure 20-41-5] from the lift
arm by-pass control valve. After removing the lift arm by-
pass valve mounting bolts move the wire harness and by-
pass valve towards the engine to give more room for
control valve removal.

P-48881

Remove the tubeline clamp (Item 1) [Figure 20-41-5].


This will allow room to move the auxiliary tubelines away
from the control valve.

T190 Bobcat Loader


20-41-2 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-7
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Removal and Installation (Cont’d)

Figure 20-41-6
2
1

1 4 1

2
P-48896
3

Label and disconnect the actuator electrical connectors


(Item 1) [Figure 20-41-7].
P-48895
Remove the bolt (Item 2) [Figure 20-41-7] from the wire
harness clamp.
Label and disconnect the electrical connectors (Item 1)
[Figure 20-41-6]. Installation: Tighten the bolt to 25-28 ft.-lbs. (34-38 Nm)
torque.
Disconnect the outlet tubeline (Item 2) [Figure 20-41-6]
from the control valve. Figure 20-41-8
Disconnect and cap the brake block hose (Item 3)
[Figure 20-41-6] from the control valve.
1 2
Remove the wire harness clamp bolt (Item 4) [Figure 20-
41-6].

P-48884

Remove the drain tubeline (Item 1) [Figure 20-41-8] from


the control valve and BICS™ valve.

Disconnect the auxiliary tubelines (Item 2) [Figure 20-41-


8].

Disconnect the drain hose (Item 3) [Figure 20-41-8] from


the control valve.

T190 Bobcat Loader


20-41-3 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-11
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Removal and Installation (Cont’d)


1
Figure 20-41-9

P-48884
1

Connect a hoist (Item 1) [Figure 20-41-11] to the control


valve.
P-48899

Disconnect the lift tubeline (Item 1) [Figure 20-41-9].

Disconnect the tilt tubeline (Item 2) [Figure 20-41-9].

Disconnect the tilt tubeline (Item 3) [Figure 20-41-9].

Figure 20-41-10
Figure 20-41-12

1
2

1 P-26062

P-48898

P-26095 P-26061
Disconnect the inlet hose (Item 1) [Figure 20-41-10]
from the bottom of the control valve.
Remove the two mounting bolts (Item 1) [Figure 20-41-
12] fastening the control valve and bracket to the side of
Disconnect the BICS valve electrical connector (Item 2)
the loader.
[Figure 20-41-10].
Remove the control valve from the loader [Figure 20-41-
12].

Reverse procedure for installation.

T190 Bobcat Loader


20-41-4 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-15
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

BICS™ Valve Removal And Installation

Figure 20-41-13

1 1
1
1

2
1 1

N-18697

1
1 Remove the four large O-rings (Item 1) and the small O-
ring (Item 2) [Figure 20-41-15] from the top of the control
N-18679 valve.

Install the four large O-rings (Item 1) and the small O-ring
Remove the control valve. (See Removal and Installation (Item 2) [Figure 20-41-15] on the top of the control valve.
Page 20-41-1.)

To remove the BICS™ from the control valve loosen and


remove the six mounting bolts (Item 1) [Figure 20-41-
13].

Figure 20-41-14

N-18695

Remove the BICS™ valve assembly from the top of the


control valve [Figure 20-41-14].

T190 Bobcat Loader


20-41-5 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

BICS Valve Removal And Installation (Cont’d)

Figure 20-41-16

3 6

1 2

5 4

N-18679

Install the six mounting bolts [Figure 20-41-16].

The chart below lists the correct torque specifications


and tightening sequence when reinstalling the BICS
valve assembly to the control valve. Thoroughly clean
and dry bolts and threads in valve. Use liquid adhesive
LOCTITE #242 or equivalent.

STEP TORQUE SEQUENCE


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

*Torque must be 190-210 in.-lbs. (21,5-23,7 Nm) for


every bolt or repeat step 3.

T190 Bobcat Loader


20-41-6 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-18
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

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


Installation

Figure 20-41-17

N-18687

1
Figure 20-41-19

N-18686

Remove the fitting (Item 1) [Figure 20-41-17] from the


valve.

N-18685

Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-41-18] & [Figure 20-41-
19].

Orifice size is 0.078 inch.

Reverse the removal procedure to install the lift arm by-


pass orifice.

T190 Bobcat Loader


20-41-7 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-22
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

BICS™ Valve, Check Valve Removal And Installation

Figure 20-41-20 1

1 P-8956

Clean and inspect the screen (Item 1) [Figure 20-41-22]


on the end of the valve.
N-18683
Reverse the removal procedure to install the BICS™
check valve.
Remove the check valve (Item 1) [Figure 20-41-20].

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


torque.

Figure 20-41-21

2
1

N-18684

Remove the O-rings (Item 1) and back-up ring (Item 2)


[Figure 20-41-21].

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


[Figure 20-41-21] on the check valve.

Check valve (Item 3) [Figure 20-41-21] has a rating of 5-


10 PSI.

T190 Bobcat Loader


20-41-8 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-25
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

BICS™ Valve Lock Valve Removal And Installation

Figure 20-41-23

1
1
1

N-18689

Remove the lock valves (Item 1) [Figure 20-41-23],


[Figure 20-41-24] & [Figure 20-41-25] from the BICS™
N-18682 valve.

Installation: Tighten the lock valves to 25 ft.-lbs. (34 Nm)


Figure 20-41-24 torque.

N-18688

T190 Bobcat Loader


20-41-9 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-28
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

BICS Valve Lock Valve Removal And Installation


(Cont’d) 1

Figure 20-41-26 1

N-18693

2 Remove the O-rings (Item 1) [Figure 20-41-28] from


2 both ends of the solenoid.
2
N-18690 Figure 20-41-29

Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-41-26] from both the tilt and lift lock valves. 1

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


[Figure 20-41-26] on the tilt and lift lock valves.

Reverse the removal procedure to install the lock valve.

BICS™ Valve Solenoid Removal And Installation

Figure 20-41-27

N-18692
1

Remove the solenoid cartridge (Item 1) [Figure 20-41-


29].

2 Installation: Tighten the cartridge to 20 ft.-lbs. (27 Nm)


torque.

N-18691

Remove the mounting nut (Item 1) [Figure 20-41-27]


from the solenoid cartridge.

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


Nm) torque.

Remove the solenoid (Item 2) [Figure 20-41-27].

T190 Bobcat Loader


20-41-10 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) BICS™ Valve Solenoid Testing
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-41-31
BICS Valve Solenoid Removal And Installation
(Cont’d)

Figure 20-41-30

3
2

P9175
1
Use an Ohm meter to measure coil resistance [Figure
N-18694 20-41-31].

Coil wires do not have polarity.


Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-41-30] from the cartridge. Correct resistance for the BICS™ is 9.7 ± 1 Ohm at 20°C.
Clean all parts in solvent and dry with compressed air. Correct resistance for the tilt and lift lock coils is 7.7 ± 1
Ohm at 20°C.
Inspect all parts for wear and replace any showing
excessive wear.

NOTE: The screen (Item 3) [Figure 20-41-30] may be


cleaned with solvent. If it is torn or worn it
needs to be replaced.

Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.

Install new O-rings (Item 1) [Figure 20-41-28] & [Figure


20-41-30] and new back-up rings (Item 2) [Figure 20-41-
30] on the solenoid cartridge.

T190 Bobcat Loader


20-41-11 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-34
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Actuator Removal And Installation

NOTE: Actuators can be removed with the control


valve in the loader. Remove the lift arm by-
pass valve to allow room for actuator removal
in the loader.
4
Figure 20-41-32
3
2

1 1 N-19114

Remove the actuator (Item 1) [Figure 20-41-34].

Remove the O-ring (Item 2) [Figure 20-41-34].

Remove the spacer block (Item 3) [Figure 20-41-34].


1
Remove the O-ring (Item 4) [Figure 20-41-34].
2 N-19112
Figure 20-41-35
Remove the two screws (Item 1) [Figure 20-41-32] on
the actuator retainer.

Installation: Tighten the bolt and nut to 90-100 in.-lbs.


(10,2-11,3 Nm) torque.

Pull the actuator (Item 2) [Figure 20-41-32] away from


the control valve.

Figure 20-41-33

N-18940

Repeat removal for the other actuator [Figure 20-41-35].

NOTE: The calibration procedure must be followed


1 when replacing handle sensor, actuator or
ACS controller. (See Calibration Procedure
Page 60-120-16.)

N-19113

Use a drift pin and hammer to remove the actuator pin


(Item 1) [Figure 20-41-33] from the actuator and the lift
or tilt spool.

T190 Bobcat Loader


20-41-12 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Lift Base End Restrictor
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-41-37
Identification Chart (ACS)

ITEM T190 ACS LOADER


A1 Lift Cylinder Base End/Restrictor
A2 Tilt Cylinder Base End 1
A3 Auxiliary Hydraulics
B1 Lift Cylinder Rod End
B2 Tilt Cylinder Rod End
B3 Auxiliary Hydraulics
C1 Load Check Valve/Lift Function
C2 Load Check Valve/Tilt Function
C3 Orificed Load Check Valve/Auxiliary Function N-21159

C4 Outlet Fluid Flow


D1 Lift Spool Centering Spring Remove the BICS™ valve assembly from the control
valve. (See BICS™ Valve Removal And Installation Page
D2 Tilt Spool Centering Spring
20-41-5.)
D3 Auxiliary Spool/Centering Springs
E1 Port Relief Valve-3500PSI Remove the restrictor (Item 1) [Figure 20-41-37] from
the lift section base end port.
E2 Anti-Cavitation/Port Relief Valve-3500PSI
F1 Anti-Cavitation Valve Load Check Valve
F2 Port Relief Valve-3500PSI
Figure 20-41-38
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
1 1
H2 Plug/Port Relief (Optional)-3100PSI
H3 Auxiliary Electric Solenoid
MR Main Relief Valve-3300PSI 1
1

Figure 20-41-36
H1
H3 H2 2

N-19099

C4

G3
B3 A3 D3
Remove the BICS™ valve assembly from the control
C3
valve. (See BICS™ Valve Removal And Installation Page
G2 B2 A2 E2
D2 20-41-5.)
C2
F2 G1
B1 A1 E1
D1
Remove the four large O-rings (Item 1) and small O-ring
F1
C1 (Item 2) [Figure 20-41-38]. Always replace these O-rings
MR before installing the BICS™ valve assembly

PE1339

T190 Bobcat Loader


20-41-13 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-40
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Load Check Valve (Cont’d)

IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 3
2 N-19101

Figure 20-41-39
Remove the load check plugs (Item 1) [Figure 20-41-40].

Remove the spring (Item 2) and poppet (Item 3) [Figure


20-41-40].

Figure 20-41-41

1 1

N-19100

Mark each valve section, spool and related parts so that


they will be returned to their original valve section during
assembly.
2 N-19102
Use bolts to fasten the control valve to a work bench for
easier disassembly and assembly procedures.
The auxiliary section (Item 1) uses an orifice load check
Loosen the load check valve plugs (Item 1) [Figure 20- poppet (Item 2) [Figure 20-41-41].
41-39].

Installation: Always use new O-ring. tighten the plug to


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

T190 Bobcat Loader


20-41-14 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-44
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
2
Main Relief Valve 3 4 5

Figure 20-41-42
1

B-06764

1. Relief Valve
2. O-ring
3. Sleeve
4. Glide Ring
5. O-ring
CD-15092

1
Remove the O-rings, sleeve, and glide ring from the main
relief valve [Figure 20-41-44].
N-19034
Installation: Always use new O-rings, sleeve, and glide
ring. TIghten to 35-40 ft.-lbs. (47-54 Nm) torque.
Loosen the main relief valve (Item 1) [Figure 20-41-42].
Port Relief Valve
Figure 20-41-43
Figure 20-41-45

1
1

N-19035

N-19000

Remove the main relief valve (Item 1) [Figure 20-41-43].

T190 Bobcat Loader


20-41-15 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-48
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
4
Port Relief Valve (Cont’d)
3
Figure 20-41-46

2
1

1
1. O-ring
2. Backup Washer
3. O-ring
4. Relief Valve
N-18844

Remove the O-rings and back-up washer from the port


relief valve [Figure 20-41-48].
N-19034
Anti-Cavitation Valve/Port Relief Valve
Loosen the port relief valve (Item 1) [Figure 20-41-45] & Figure 20-41-49
[Figure 20-41-46] (Port E1 or F2). (See Identification
Chart (ACS) Page 20-41-13.)

Installation: Always use new O-rings and back-up


washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
1
Figure 20-41-47

N-19003
1

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


49].

N-18981

Remove the port relief valve (Item 1) [Figure 20-41-47].

T190 Bobcat Loader


20-41-16 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Anti-Cavitation Valve
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-41-52
Anti-Cavitation Valve/Port Relief Valve (Cont’d)

Figure 20-41-50
1

N-19034

N-18980 Figure 20-41-53

Remove the anti-cavitation/port relief valve (Item 1) from


the control valve for the tilt section [Figure 20-41-50].

Installation: Always use new O-rings and back-up


washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.

Figure 20-41-51

1
N-19036

Remove the anti-cavitation valve (Item 1) [Figure 20-41-


52] & [Figure 20-41-53] from the control valve.

N-18843

Remove the O-rings (Item 1) [Figure 20-41-51] from the


anti-cavitation/port relief valve.

T190 Bobcat Loader


20-41-17 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-56
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Anti-Cavitation Valve (Cont’d)

Figure 20-41-54

1 2 4
3

E-1509A 1
1

1. Anti-Cavitation Valve
N-19003
2. O-ring
3. Backup Washer
4. O-ring Remove the screws (Item 1) [Figure 20-41-56] from the
cap.
N-18839
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
Remove the O-rings and back-up washer from the anti-
cavitation valve [Figure 20-41-54]. Figure 20-41-57
Tilt Spool Removal And Installation

Figure 20-41-55

N-18983

Remove the spool assembly (Item 1) [Figure 20-41-57]


N-19112 and seal from the control valve.

Assembly: Always use a new spool seal.


Remove the actuator (Item 1) [Figure 20-41-55] from the
control valve. (See Actuator Removal And Installation
Page 20-41-12.)

T190 Bobcat Loader


20-41-18 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-60
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Lift Spool Removal And Installation

Figure 20-41-58

N-18985

Remove the spool assembly (Item 1) [Figure 20-41-60]


and seal from the control valve.
N-19112
Assembly: Always use a new spool seal.
Remove the actuator (Item 1) [Figure 20-41-58] from the Lift and Tilt Spool Disassembly And Assembly
control valve. (See Actuator Removal And Installation
Page 20-41-12.) Figure 20-41-61
Figure 20-41-59

1
1

N-18942

N-19003
Put the linkage end of the spool in the vice [Figure 20-
41-61].
Remove the screws (Item 1) [Figure 20-41-59] from the
end cap. Install the spool tool (Item 1) [Figure 20-41-61] over the
centering spring.
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.

T190 Bobcat Loader


20-41-19 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-64
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Lift and Tilt Spool Disassembly And Assembly 2


(Cont’d)
1
Figure 20-41-62

1 1

N-18930 N-18943

Remove the spool seal(s) (Item 1) and the back-up


washer (Item 2) [Figure 20-41-64].

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

Auxiliary Spool Removal And Installation


Remove the bolt (Item 1) [Figure 20-41-62] holding the
centering spring to the spool. Figure 20-41-65
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.

Remove spring tool from the spring assembly.

Figure 20-41-63

1
2 1
3

N-19003

Remove the screws (Item 1) [Figure 20-41-65] from the


end cap (both sides).

Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3


N-18944A Nm) torque.

Inspect the adapter (Item 1) [Figure 20-41-63], collar


(Item 2) [Figure 20-41-63], spring (Item 3) [Figure 20-
41-63], and washer (Item 4) [Figure 20-41-63].

T190 Bobcat Loader


20-41-20 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Auxiliary Electric Solenoid
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-41-68
Auxiliary Spool Removal And Installation (Cont’d)

Figure 20-41-66

4
3

2
1 1

1
N-18996

N-18987 Remove the nut (Item 1) [Figure 20-41-68] from both


solenoids.
Remove the end cap (Item 1), O-ring (Item 2) springs Installation: Tighten the nut to 96-144 in.-lbs. (11-16
(Item 3) and washer (Item 4) [Figure 20-41-66] (both Nm) torque.4
sides).
Figure 20-41-69
Assembly: Always use a new spool seal.

Figure 20-41-67

1
2

N-18823

N-18988 Remove the end plate (Item 1) and housing (Item 2)


[Figure 20-41-69].

Remove the spool (Item 1) [Figure 20-41-67].

Assembly: Put grease on all the centering spring


component parts.

T190 Bobcat Loader


20-41-21 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-71
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Auxiliary Electric Solenoid (Cont’d)

Figure 20-41-70

3
2 1

1
N-18795

Remove the O-rings (Item 1) [Figure 20-41-71] from the


solenoid valves.
N-18992
Installation: Always use new O-rings and apply oil to the
O-rings prior to installation.
Remove the coil (Item 1) and end plate (Item 2) [Figure
20-41-70].

Remove the solenoid valve (Item 3) [Figure 20-41-70].

Installation: Tighten valve to 96-144 in.-lbs. (11-16 Nm)


torque.

T190 Bobcat Loader


20-41-22 Service Manual
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-41-74
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Port-Auxiliary Section

Figure 20-41-72

2 1

N-18843
1

Remove the O-rings (Item 1) [Figure 20-41-73] &


[Figure 20-41-74] and back-up ring (Item 2) [Figure 20-
N-18996 41-73] & [Figure 20-41-74] from the plug.

Cleaning And Inspection


Remove the plug (Item 1) [Figure 20-41-72] or optional
port relief valve from the control valve. Clean all components with clean solvent and dry with
compressed air.
Figure 20-41-73
Check the spools for wear or scratches.
Plug
Check that the spools are not loose in their bore.

Check that the centering springs are not broken.


2
Check that the load check valve seats are not worn.

Check the load check poppets for damage.

1 Check the rubber boots and retainers.

1 Replace the parts as needed.

N-18800 Use new O-rings and back-up rings.

Apply oil to all new O-rings and back-up rings before


installation.

T190 Bobcat Loader


20-41-23 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(FOOT CONTROL)

Identification IMPORTANT
Figure 20-42-1 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

1
Lift and block the loader. ((See Procedure on Page 10-
10-1.)

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

Raise the operator cab. (See Raising The Operator Cab


P-51436
on Page 10-30-1.)

The hydraulic control valve (1 piece casting) (foot control) Clean the area around the control valve.
(Item 1) [Figure 20-42-1] does not have a removable
BICS™ section. Drain the hydraulic reservoir. (See Replacing Hydraulic
Fluid on Page 10-120-2.)
The BICS™ section and main control valve are in one
casting. Remove the control panel. (See Removal and Installation
on Page 50-100-1.)
For identification of the hydraulic control valve (2 piece
casting) (foot control), (See Identification on Page 20-40- Figure 20-42-2
1.)

Removal And Installation

P-51710

WARNING Mark all tubelines and hoses for correct installation.


Never work on a machine with the lift arms up unless
The fixed end main valve hose (Item 1) [Figure 20-42-2]
the lift arms are secured by an approved lift arm
is connected to a fixed end fitting on the control valve.
support device. Failure to use an approved lift arm
The hose is routed to the back upright where the hose is
support device can allow the lift arms or attachment
connected to a tee fitting that feeds the base end of both
to fall and cause injury or death.
W-2059-0598 lift cylinders. The hose must be removed at the back tee
fitting, located in the right side upright.

NOTE: Remember the hose routing for ease of

T190 Bobcat Loader


20-42-1 Service Manual
control valve installation. HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(FOOT CONTROL) (CONT’D)

Removal and Installation (Cont’d)

Figure 20-42-3

P-51711

Remove the tie-strap (Item 1) [Figure 20-42-3] from the


fixed end main valve hose.

Figure 20-42-4

2 1

3
1

P-51714

Mark and disconnect the four electric solenoid


connectors for correct installation (Item 1) [Figure 20-42-
4].
Remove the outlet tubeline (Item 2) [Figure 20-42-4]
from the control valve to the hydraulic oil cooler.

Disconnect and cap the supply hose (Item 3) and the


supply hose clamp (Item 4) [Figure 20-42-4].

T190 Bobcat Loader


20-42-2 Service Manual
Figure 20-42-5 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(FOOT CONTROL) (CONT’D)

Removal And Installation (Cont'd)

Figure 20-42-7

P-51725

Disconnect and cap the brake block hose (Item 1)


[Figure 20-42-5] from the control valve.
P-51719
Figure 20-42-6

Remove the tie-strap (Item 1) [Figure 20-42-7] from the


1 main valve mounting bracket.

Figure 20-42-8

2 2

P-51715 1

Disconnect and cap the tubeline (Item 1) [Figure 20-42-


6] from the lift arm by-pass valve to the control valve.
P-51724
Disconnect and cap the hose (Item 2) [Figure 20-42-6]
from the lift arm by-pass valve to the drive motor case
drain. Disconnect the wire harness tie-strap mounts (Item 1)
[Figure 20-42-8] from the lift arm by-pass bracket.

Remove the lift arm by-pass tubeline (Item 2) [Figure


20-42-8] from the control valve drain.

T190 Bobcat Loader


20-42-3 Service Manual
Figure 20-42-9 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(FOOT CONTROL) (CONT’D)

Removal And Installation (Cont'd)

Figure 20-42-11
1

1 1

P-48287

Remove the connector pins (Item 1) [Figure 20-42-9].

Figure 20-42-10 P-51721

Remove the two lift arm by-pass valve mounting bolts


(Item 1) [Figure 20-42-11].
1
Remove the lift arm by-pass valve and mounting bracket.

Figure 20-42-12

P-51723

NOTE: Skid loader transmission shown, procedure is


the same.

Remove the wire harness clamp bolt (Item 1) [Figure 20-


42-10].
P-51727
Remove the control pedal crossbar linkage and tilt
linkage. (See Linkage Removal And Installation on Page
50-100-5.) Remove tubeline clamp bolt (Item 1) [Figure 20-42-13]
from the auxiliary tubelines in the left rear upright.

Installation: Tighten bolt to 15-20 ft.-lbs. (20-27 Nm)


torque.

T190 Bobcat Loader


20-42-4 Service Manual
Figure 20-42-13 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(FOOT CONTROL) (CONT'D)

Removal And Installation (Cont'd)

Figure 20-42-15
2
1 1

P-51714

1
Remove and cap both tubelines (Item 1) [Figure 20-42-
13] from the auxiliary section of the control valve.
P-51728
Disconnect and cap the drain hose (Item 2) [Figure 20-
42-13] from the control valve.
Remove the fixed-end main valve hose (Item 1) [Figure
Figure 20-42-14 20-42-15] from the main control valve fitting.

Figure 20-42-16

3 1

P-51729

P-51722
Disconnect and cap the tubelines (Item 1) and (Item 2)
[Figure 20-42-14] from the tilt section of the control
valve. Mark and disconnect the BICS™ electric solenoid
connector (Item 1) [Figure 20-42-16].
Disconnect and cap the tubeline (Item 3) [Figure 20-42-
14] from the lift section of the control valve.

T190 Bobcat Loader


20-42-5 Service Manual
Figure 20-42-17

1 1

P-51726

Connect a hoist to the lifting brackets (Item 1) [Figure 20-


42-17] on the control valve.

Figure 20-42-18

1
P-26095A
1

P-26062A P-51713

Remove the two mounting bolts (Item 1) [Figure 20-42-


18] fastening the control valve and bracket to the side of
the loader.

Remove the control valve from the loader [Figure 20-42-


18].

Reverse procedure for installation.

T190 Bobcat Loader


20-42-6 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)

Identification Chart

Figure 20-42-19

C2 J2 C3
J4
D5 B3
E3
E3
G1 G2

F2 A3 D3
B2
D4 F4 E2
A2

D1
D2
A1
E1
F1 H2 B1
F3 H3
MR C1
H1 J3
J1
MS1926

ITEM T190 LOADER ITEM T190 LOADER


A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 LIft Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Load Check/BICS™ Valve F4 Tilt Spool Lock Solenoid
Lift G1 Auxiliary Solenoid Stem
C2 Load Check Valve Tilt Function G2 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function H1 BICS™ Valve Solenoid
D1 Anti-Cavitation Valve
H2 BICS™ Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief/Anti-Cavitation Valve – 3500 PSI H3 BICS™ Lock Valve (Lift)
Lift (Base End) J1 Inlet Fluid Flow (From Pump)
D3 Port Relief/Anti-Cavitation Valve – 3500 PSI J2 Outlet Fluid Flow (Return to Tank)
Tilt (Base End)
J3 Lift Arm By-Pass Orifice
D4 Port Relief/Anti-Cavitation Valve – 3500 PSI
J4 Drain (Case)
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary) MR Main Relief Valve – 3300 PSI
3500 PSI (Optional)

T190 Bobcat Loader


20-42-7 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) BICS™ Valve, Lift Load Check Valve Removal And
(FOOT CONTROL) (CONT'D) Installation

Mount Bracket Removal and Installation Figure 20-42-22

Figure 20-42-20

1 P-51438

P-51690
Remove the lift load check valve (Item 1) [Figure 20-42-
22].
Remove the control valve and mount bracket (Item 1)
[Figure 20-42-20] from the loader. Installation: Lubricate the o-ring and tighten the valve to
55-65 ft.-lbs. (75-88 Nm) torque.
Figure 20-42-21
Figure 20-42-23

2 1

2
2

P-51435

P-51439

Disconnect the tubeline (Item 1) [Figure 20-42-21] from


the inlet fitting on the control valve. Remove and install new O-rings (Item 1) and back-up
ring (Item 2) [Figure 20-42-23].
Remove the two mount bolts (Item 2) [Figure 20-42-21]
from the control valve mount plate. Remove the mount
plate and tubeline.

T190 Bobcat Loader


20-42-8 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-26
(FOOT CONTROL) (CONT'D)

BICS™ Valve, Lift Load Check Valve Removal And


Installation (Cont’d)
4
Figure 20-42-24

1 1
3
2

P-51453

Remove the spring (Item 1) and poppet (Item 2) [Figure


20-42-26].

P-51440 Check the orifice (Item 3) [Figure 20-42-26] in the


poppet to be sure it is not plugged.
Check for free movement of the load check valve (Item 1) Installation: Install a new O-ring (Item 4) [Figure 20-42-
[Figure 20-42-24]. 26] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lbs. (52-61 Nm)
Load Check Valve Removal And Installation (Tilt & torque.
Auxiliary)

Figure 20-42-25

P-51691

At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-42-25].

At the front side of the control valve locate the auxiliary


section load check valve (Item 2) [Figure 20-42-25].

NOTE: The tilt and auxiliary load check valves are


interchangeable.

T190 Bobcat Loader


20-42-9 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-29
(FOOT CONTROL) (CONT'D)

Anti-Cavitation Valve (Lift, Rod End)


4
Figure 20-42-27

1
3
2

1 P-51453

Remove the spring (Item 1) and poppet (Item 2) [Figure


20-42-29].
P-51692
Check the orifice (Item 3) [Figure 20-42-29] in the
poppet to be sure it is not plugged.
At the back side of the control valve, remove the lift
Installation: Install a new O-ring (Item 4) [Figure 20-42-
section anti-cavitation valve (Item 1) [Figure 20-42-27]. 29] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lbs. (52-61 Nm)
torque.

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

Figure 20-42-28

P-51693

Installation: Always use new O-ring (Item 1) [Figure 20-


42-28] on the anti-cavitation valve plug.

T190 Bobcat Loader


20-42-10 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Tilt, Base End)
(FOOT CONTROL) (CONT'D)
Figure 20-42-32
Port Relief/Anti-Cavitation Valve (Lift, Base End)

Figure 20-42-30

P-51692

P-51692 Remove the tilt port relief/anti cavitation valve (Item 1)


[Figure 20-42-32] from the base end of the tilt section.
Loosen the lift circuit port relief/anti cavitation valve (Item Figure 20-42-33
1) [Figure 20-42-30].

Figure 20-42-31

P-51454
1
Replace the O-ring (Item 1) [Figure 20-42-33] before
P-51451
installation.

Replace the O-ring (Item 1) [Figure 20-42-31] before Installation: Tighten to 38-45 ft.-lbs. (52-61 Nm) torque.
installation.

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

T190 Bobcat Loader


20-42-11 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief Valve
(FOOT CONTROL) (CONT'D)
Figure 20-42-36
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)

Figure 20-42-34

P-51692

P-51692 Remove the port relief plug (Item 1) [Figure 20-42-36]


from the auxiliary circuit of the control valve.
Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-42-37
[Figure 20-42-34] from the rod end of the tilt section.

Figure 20-42-35

1 P-51695

P-51694 Installation: Always use new O-rings (Item 1) [Figure


20-42-37]. Tighten to 38-45 ft.-lbs. (52-61 Nm) torque.

Replace the O-ring (Item 1) [Figure 20-42-35] before


installation.

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

T190 Bobcat Loader


20-42-12 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Plug Removal
(FOOT CONTROL) (CONT'D)
Figure 20-42-40
Port Relief Valve (Cont’d)

Figure 20-42-38

1 1

P-51459

P-51696 At the top side of the control valve, remove the plug (Item
1) [Figure 20-42-40].
The control valve may be equipped with an optional Figure 20-42-41
auxiliary port relief valve (Item 1) [Figure 20-42-38].

Remove the auxiliary port relief valve.

Figure 20-42-39

1
P-51460

Installation: Always use new O-rings (Item 1) [Figure


20-42-41]. Tighten to 40 ft.-lbs. (54 Nm) torque.
P-51640

Installation: Always use new O-rings (Item 1) [Figure


20-42-39]. Tighten to 38-45 ft.-lbs. (52-61 Nm) torque.

T190 Bobcat Loader


20-42-13 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Rubber Boot Removal and Installation
(FOOT CONTROL) (CONT'D)
Figure 20-42-44
Plug Removal (Cont’d)
1
Figure 20-42-42

P-51506

1
P-51461 Remove the three screws (Item 1) [Figure 20-42-44] on
the rubber boot retainer plate.
At the bottom side of the control valve remove the plug Installation: Tighten the screws to 90-100 in.-lbs. (10-
(Item 1) [Figure 20-42-42]. 11,3 Nm) torque.
Figure 20-42-43 Figure 20-42-45

1
2
1

P-51462
P-51701

Installation: Always use new O-rings (Item 1) [Figure Remove the rubber boots (Item 1) from the retainer plate
20-42-43]. Tighten to 40 ft.-lbs. (54 Nm) torque. (Item 2) [Figure 20-42-45].

T190 Bobcat Loader


20-42-14 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-48
(FOOT CONTROL) (CONT'D)

End Cap/Spool Lock Block Removal and Installation

Figure 20-42-46

1 1

P-51699
1

Remove the four end cap/spool lock block mount screws


(Item 1) [Figure 20-42-48].
P-51697
Installation: Tighten the screws to 90-100 in.-lbs. (10-
11,3 Nm) torque.
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-42-46] from the Remove the rubber boots and retainer plate from the lift
end cap/spool lock block. and tilt spools.
Installation: Tighten the solenoids to 38-45 ft.-lbs. (52- Figure 20-42-49
61 Nm) torque.

Figure 20-42-47

1
P-51700

P-51698 Remove the end cap/spool lock block (Item 1) [Figure


20-42-49] from the control valve.

Disconnect the tube line (Item 1) [Figure 20-42-47] from


the end cap/spool lock block.

T190 Bobcat Loader


20-42-15 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-52
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation

The tool listed will be needed to do the following


procedure:

MEL1278 - Detent Tool


MEL1285 - Detent Spring Tool 1

Remove the end cap/spool lock block from the control


valve.

Figure 20-42-50
P-51513

Remove the end cap (Item 1) [Figure 20-42-52].

Figure 20-42-53
1

P-51511
1
Remove the O-ring (Item 1) [Figure 20-42-50]. 2

Installation: Replace the O-ring, and lubricate lightly


with oil before installation of the end cap/spool lock block.
P-51514

Figure 20-42-51
Use a screwdriver to remove the snap ring (Item 1)
[Figure 20-42-53].

Remove the washer (Item 2) [Figure 20-42-53].

P-51512

Remove the spacer (Item 1) and O-ring (Item 2) [Figure


20-42-51] from the lift spool.

T190 Bobcat Loader


20-42-16 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-56
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)

Figure 20-42-54

2 1
3

1 2 P-51517

Remove the detent sleeve (Item 1), detent balls (Item 2)


and spring (Item 3) [Figure 20-42-56].
1 2
P-51515 Figure 20-42-57

Remove the screws (Item 1) [Figure 20-42-54] from the


detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-42-54].
Installation: Lubricate the screws and tighten to 90-100
in.-lbs. (10-11,3 Nm) torque.

WARNING
The detent assembly has small springs and balls. Do 1
not lose these parts during disassembly and
assembly.
P-51518

Figure 20-42-55 Remove the lift spool assembly and seal (Item 1) [Figure
20-42-57] from the control valve.

P-51516

Put a rag around the detent assembly [Figure 20-42-55].


This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.
T190 Bobcat Loader
20-42-17 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-60
(FOOT CONTROL) (CONT'D)
2
Lift Spool and Detent Removal and Installation
(Cont'd)

Figure 20-42-58 1
3

N-18915

1 Install the spring tool (Item 1) [Figure 20-42-60] over the


centering spring.

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


(Item 2) [Figure 20-42-60] from the centering
spring, as it is under spring pressure.
Remove the lift spool seal (Item 1) [Figure 20-42-58]
from the linkage end of the valve. NOTE: The centering spring (Item 3) [Figure 20-42-60]
is white on all 700 series loaders.
Figure 20-42-59
Figure 20-42-61

1
P-8988 2
N-18916

Clamp the linkage end of the spool in a vise [Figure 20-


42-59]. Put a rag around the detent assembly [Figure 20-42-61].
This will prevent the detent balls and spring from being
NOTE: Protect spool before clamping in vise. lost when the detent adapter is removed.

Remove the detent adapter with an Alan wrench.

Remove the back-up washer (Item 1) and spool seal


(Item 2) [Figure 20-42-61].

T190 Bobcat Loader


20-42-18 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-64
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation 1


2
(Cont'd)
3
Figure 20-42-62

1 4

N-18919A

Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-42-64].

N-19004 Figure 20-42-65

Remove the detent adapter (Item 1) [Figure 20-42-62]


from the spring assembly.

Figure 20-42-63

N-18918

Remove the stud from the end of the spool [Figure 20-
42-65].

N-19009

Remove spring tool (Item 1) [Figure 20-42-63] from the


spring assembly.

T190 Bobcat Loader


20-42-19 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-68
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)

Figure 20-42-66

N-18963

1
Install the plastic plug and O-ring in the spool [Figure 20-
42-68].

N-18920 Figure 20-42-69

Removal of the plastic plug: O-ring

Make a center point in the plug using a 1/16 inch drill.

Drill a hole all the way through the plug using a 7/64 inch
tap drill

Turn a 6-32 tap (Item 1) [Figure 20-42-66] into the plug.


Pull the tap and plug out of the spool. Be careful, do not
Plastic
break the tap.
Plug
0.60 inch
Clean all the debris from inside the spool bore. (15,2 mm)

NOTE: DO NOT USE LOCTITE ON THE STUD


B-14712
THREADS.

Figure 20-42-67
Install the stud and tighten until the other end of the stud
is out about 0.600 inch (15,2 mm) from the spool [Figure
20-42-69].

2
1

N-18961

Install the O-ring (Item 1) over the nipple on the plastic


plug (Item 2) [Figure 20-42-67].

T190 Bobcat Loader


20-42-20 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-72
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)

Figure 20-42-70

1
1

N-18968

Install the detent adapter to the collar [Figure 20-42-72].

NOTE: The collar and the detent adapter are held


N-18967 together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
Clamp the collar (Item 1) [Figure 20-42-70] in a vice. the detent balls and spring from falling out.
Figure 20-42-71 Figure 20-42-73

1 3
2

N-18958
N-19004

Apply grease on all the detent component surfaces Install the spring tool (Item 1) [Figure 20-42-73] over the
before assembly [Figure 20-42-71]. washer, spring, collar and detent adapter.

Install the spring (Item 1) and detent balls (Item 2) into


the adapter (Item 3) [Figure 20-42-71] and compress
with the detent pliers (Item 1) [Figure 20-42-72].

T190 Bobcat Loader


20-42-21 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-76
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)

Figure 20-42-74

CD-15051

1
Install the detent balls and spring [Figure 20-42-76].

Figure 20-42-77
N-18917

Install the spool seal (Item 1) and back-up washer (Item


2) [Figure 20-42-74].

Figure 20-42-75

1
N-19007

Hold the detent balls in place with the detent pliers


[Figure 20-42-77].

N-19005

Install the spring assembly to the lift spool hand tight


[Figure 20-42-75].

Remove the spring tool.

Check the alignment of the detent adapter and the


washer.

Tighten the adapter to 90-100 in.-lbs. (10,2-11,3 Nm).

NOTE: The adapter must fit in the center of the


washer (Item 1) [Figure 20-42-75].

T190 Bobcat Loader


20-42-22 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-80
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)

Figure 20-42-78

1
P-51514

Install the washer (Item 1) and snap ring (Item 2) [Figure


20-42-80].

N-19008 Figure 20-42-81

Install the detent sleeve (Item 1) [Figure 20-42-78] to the


detent adapter.

Figure 20-42-79

2
P-51513

1
Install the end cap (Item 1) [Figure 20-42-81].

2
P-51515

Install the lift spool assembly in the spool bore [Figure


20-42-79].

Install the detent bonnet (Item 1) [Figure 20-42-79].

Install the mounting screws (Item 2) [Figure 20-42-79].

Installation: Lubricate the screws and tighten to 90-100


in.-lbs. (10-11,3 Nm) torque.

T190 Bobcat Loader


20-42-23 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-84
(FOOT CONTROL) (CONT'D)

Lift Spool and Detent Removal and Installation


(Cont'd)

Figure 20-42-82 1

P-51511

Install the O-ring (Item 1) [Figure 20-42-80] on the


control valve.

P-51520 Figure 20-42-85

Install the spool seal (Item 1) [Figure 20-42-82] on the


linkage end of the valve. 2

Figure 20-42-83

1 4
P-51701

2 Install the end cap/spool lock block (Item 1) and the


mount bolt (Item 2) [Figure 20-42-81].

P-51512 Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-42-81].
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-42-83] on the lift spool. Installation: Tighten the screws to 90-100 in.-lbs. (10-
11,3 Nm) torque.

T190 Bobcat Loader


20-42-24 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Tilt Spool Removal and Installation
(FOOT CONTROL) (CONT'D)
Remove the lift and tilt end cap/spool lock block. (See
Lift Spool and Detent Removal and Installation End Cap/Spool Lock Block Removal and Installation on
(Cont'd) Page 20-42-14.)

Figure 20-42-86 Figure 20-42-88

1 2

P-51698
P-51521

Connect the tubeline (Item 1) [Figure 20-42-86]. Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-42-88] from the tilt spool.
Figure 20-42-87
Figure 20-42-89

1
P-51697

P-51522

Use an Ohm meter to measure the lock solenoid coils


resistance. Remove the three screws (Item 1) [Figure 20-42-89]
from the spool centering block.
The correct resistance for the coil is 5.5 ± .28 Ohms.
Installation: Tighten the bolt to 90-100 in.-lbs. (10-11,3
Installation: Install the lift spool (Item 1) and tilt spool Nm) torque.
(Item 2) [Figure 20-42-87] lock solenoids and tighten to
38-45 ft.-lbs. (52-61 Nm) torque.

T190 Bobcat Loader


20-42-25 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-92
(FOOT CONTROL) (CONT'D)

Tilt Spool Removal And Installation (Cont'd)


1
Figure 20-42-90

N-18942

1 Put the linkage end of the spool in the vice [Figure 20-
42-92].
P-51543
Install the spool tool (Item 1) [Figure 20-42-92] over the
centering spring.
Remove the spool centering block (Item 1) [Figure 20-
42-90] from the control valve. Figure 20-42-93
Check and replace the O-ring (Item 2) [Figure 20-42-90]
before replacing the spool centering block.
1
Figure 20-42-91

N-19014

Remove the bolt (Item 1) [Figure 20-42-93] holding the


centering spring to the spool.
P-51544
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
Remove the tilt spool, centering spring, back-up washer
and spool seal [Figure 20-42-91]. Remove spring tool from the spring assembly.

Assembly: Always use a new spool seal.

T190 Bobcat Loader


20-42-26 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Auxiliary Spool Removal And Installation
(FOOT CONTROL) (CONT'D)
Figure 20-42-96
Tilt Spool Removal And Installation (Cont'd)

Figure 20-42-94

2 1
3 1

P-51522

N-18944A Remove the three screws (Item 1) [Figure 20-42-96]


from the spool centering block.
Inspect the adapter (Item 1), collar (Item 2), spring (Item Installation: Tighten the bolt to 95 in.-lbs. (11 Nm)
3) and washer (Item 4) [Figure 20-42-94]. torque.
Figure 20-42-95 Remove the spool centering block (Item 2) [Figure 20-
42-96] from the control valve.
2
1 Figure 20-42-97

1 2
1

P-51545 N-18943

Remove the spool seal(s) (Item 1) [Figure 20-42-95] and


P-51546
the back-up washer (Item 2) [Figure 20-42-95].

Assembly: Always use a new spool seal. Remove the spring (Item 1) and center spring retainer
(Item 2) [Figure 20-42-97] from the auxiliary spool.

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


20-42-97] must be replaced, replace the
retainer on the opposite end also.

T190 Bobcat Loader


20-42-27 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-100
(FOOT CONTROL) (CONT'D)

Auxiliary Spool Removal And Installation (Cont’d)

Figure 20-42-98

1 2

1
2 P-51550

Remove the spacer (Item 1) and O-ring (Item 2) [Figure


20-42-100] from the auxiliary spool.
P-51547
Figure 20-42-101
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-42-98] from the auxiliary spool.

Figure 20-42-99

2 1
P-51551

Remove the spool (Item 1) [Figure 20-42-98].

P-51549

Remove the spring (Item 1) and center spring retainer


(Item 2) [Figure 20-42-99] from the auxiliary spool.

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


20-42-99] must be replaced, replace the
retainer on the opposite end also.

T190 Bobcat Loader


20-42-28 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-104
(FOOT CONTROL) (CONT'D)

Auxiliary Solenoid Disassembly and Assembly

Figure 20-42-102
1

P-51703

Remove the solenoid stem (Item 1) [Figure 20-42-104].

P-51702 Installation: Tighten the stem to 10-14 ft.-lbs. (14-19


Nm) torque.
Remove the nut (Item 1) [Figure 20-42-102] from both Figure 20-42-105
solenoids.

Installation: Tighten the nut to 48-72 in.-lbs. (5-8 Nm)


torque.

Figure 20-42-103
1

2
2
P-51555

Remove the O-rings (Item 1) [Figure 20-42-105] from


the solenoid stem.

P-51553 Check and clean the screen (Item 2) [Figure 20-42-105].

Remove the nut (Item 1) and solenoid coil (Item 2)


[Figure 20-42-103].

Use an Ohm meter to measure the solenoid coil


resistance.

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

T190 Bobcat Loader


20-42-29 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-108
(FOOT CONTROL) (CONT'D)

BICS™ Valve Solenoid Disassembly And Assembly

Figure 20-42-106

2
P-51445

Remove the solenoid stem (Item 1) [Figure 20-42-108].

P-51444 Installation: Lubricate the O-rings and tighten the stem


to 20-24 ft.-lbs. (27-33 Nm) torque.
Remove the nut (Item 1) [Figure 20-42-106] from the Figure 20-42-109
solenoid stem.

Installation: Tighten the nut to 53 in.-lbs. (6 Nm) torque.

Remove the solenoid coil (Item 2) [Figure 20-42-106]. 3


2
Figure 20-42-107

N-18694

Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-42-109] from the cartridge.

Clean all parts in solvent and dry with compressed air.


N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-42-107] from
both ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-42-109] may be
cleaned with solvent. If it is torn or worn it
Use an Ohm meter to measure the solenoid coil needs to be replaced.
resistance.
Use only new O-rings and apply oil to all O-rings and
The correct resistance for the coil is 9.79 ± .29 Ohms. back-up rings before installation.

Install new O-rings (Item 1) [Figure 20-42-107] &


[Figure 20-42-109] and new back-up rings (Item 2)
[Figure 20-42-109] on the solenoid stem.

T190 Bobcat Loader


20-42-30 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-112
(FOOT CONTROL) (CONT'D)

BICS™ Valve, Lock Valve Removal And Installation

Figure 20-42-110 1
1
1

1 2
1
2
2
2
P-51564

Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-42-112] from the lift lock valve, and replace
P-51704 with new.

Locate the two BICS™ lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-42-110] is for the lift
circuit.

Figure 20-42-111

P-51443

Remove the lift lock valve (Item 1) [Figure 20-42-111]


from the back of the control valve.

Installation: Lightly lubricate the lock valve o-rings and


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

T190 Bobcat Loader


20-42-31 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-115
(FOOT CONTROL) (CONT'D)

BICS™ Valve, Lock Valve Removal And Installation


(Cont’d)

Figure 20-42-113

1
P-51706

Remove the tilt lock valve (Item 1) [Figure 20-42-115]


from the front of the control valve.

P-51705 Installation: Lightly lubricate the lock valve o-rings and


tighten to 20-24 ft.-lbs. (27-33 Nm) torque.
Locate the tilt circuit lock valve (Item 1) [Figure 20-42- Figure 20-42-116
113].

Figure 20-42-114

1
1
2 1

1
2
1
2
2
P-51564

P-51697 Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-42-116] from the tilt lock valve, and replace
with new.
Remove the lift spool lock solenoid (Item 1) [Figure 20-
42-114].

Remove the tilt spool lock solenoid (Item 2) [Figure 20-


42-114].

Installation: Lubricate the O-rings and tighten the spool


lock solenoids to 38-45 ft.-lbs. (52-61 Nm) torque.

T190 Bobcat Loader


20-42-32 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-42-119
(FOOT CONTROL) (CONT'D)

BICS™ Valve, Check Valve Removal And Installation 1

Figure 20-42-117

1
4
P-51447

Check that there is no blockage in the orifice (Item 1)


[Figure 20-42-119].
P-51438
Inspect the check valve (Item 2) and spring (Item 3)
[Figure 20-42-119].
Remove the BICS™ valve (Item 1) [Figure 20-42-117].
Replace the O-ring (Item 4) [Figure 20-42-119] on the
Installation: Lubricate the o-ring and tighten the valve to plug before installation.
55-65 ft.-lbs. (75-88 Nm) torque.

Figure 20-42-118

P-51446

Remove the plug (Item 1) [Figure 20-42-118] from the


top of the BICS™ valve.

T190 Bobcat Loader


20-42-33 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Main Relief Valve
(FOOT CONTROL) (CONT'D)
Figure 20-42-122
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly
And Assembly

Figure 20-42-120

1 P-51707

Remove the main relief valve (Item 1) [Figure 20-42-


P-51436 122].

Figure 20-42-123
Remove the fitting (Item 1) [Figure 20-42-120] from the
valve.

Figure 20-42-121

1
1

P-51463

Remove the O-rings from the main relief valve (Item 1)


P-51437 [Figure 20-42-123].

Installation: Always use new O-rings. Tighten to 38-45


Check the lift arm by-pass orifice (Item 1) [Figure 20-42- ft.-lbs. (52-61 Nm) torque.
121].

NOTE: This orifice is not removable from the valve


casting.

T190 Bobcat Loader


20-42-34 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCE CONTROL SYSTEM) (ACS)

Identification IMPORTANT
Figure 20-43-1 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

1 Lift and block the loader. ((See Procedure on Page 10-


10-1.)

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

Raise the operator cab. (See Raising The Operator Cab


P-51730
on Page 10-30-1.)

The hydraulic control valve (1 piece casting) (ACS) (Item Clean the area around the control valve.
1) [Figure 20-43-1] does not have a removable BICS™
section. Drain the hydraulic reservoir. (See Replacing Hydraulic
Fluid on Page 10-120-2.)
The BICS™ section and main control valve are in one
casting. Remove the control panel. (See Removal and Installation
on Page 50-100-1.)
For identification of the hydraulic control valve (2 piece
casting) (ACS), (See Identification on Page 20-41-1.) Figure 20-43-2

Removal And Installation

P-51710

WARNING Mark all tubelines and hoses for correct installation.

The fixed end main valve hose (Item 1) [Figure 20-43-2]


Never work on a machine with the lift arms up unless
is connected to a fixed end fitting on the control valve.
the lift arms are secured by an approved lift arm
The hose is routed to the back upright where the hose is
support device. Failure to use an approved lift arm
connected to a tee fitting that feeds the base end of both
support device can allow the lift arms or attachment
lift cylinders. The hose must be removed at the back tee
to fall and cause injury or death.
W-2059-0598 fitting, located in the right side upright.

NOTE: Remember the hose routing for ease of

T190 Bobcat Loader


20-43-1 Service Manual
control valve installation. HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Removal and Installation (Cont’d)

Figure 20-43-3

P-51711

Remove the tie-strap (Item 1) [Figure 20-43-3] from the


fixed end main valve hose.

Figure 20-43-4

2
1 3

P-51975

Mark and disconnect the two auxilliary electric solenoid


connectors (Item 1) [Figure 20-43-4] for correct
installation.

Remove the outlet tubeline (Item 2) [Figure 20-43-4]


from the control valve to the hydraulic oil cooler.

Disconnect and cap the supply hose (Item 3) and the


supply hose clamp (Item 4) [Figure 20-43-4].

T190 Bobcat Loader


20-43-2 Service Manual
Figure 20-43-5 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Removal And Installation (Cont'd)

Figure 20-43-7

P-51725

Disconnect and cap the brake block hose (Item 1)


[Figure 20-43-5] from the control valve.
P-51719
Figure 20-43-6

Remove the tie-strap (Item 1) [Figure 20-43-7] from the


1 main valve mounting bracket.

Figure 20-43-8

P-51976 1

Disconnect and cap the tubeline (Item 1) [Figure 20-43-


6] from the lift arm by-pass valve to the control valve.
P-51977
Disconnect and cap the hose (Item 2) [Figure 20-43-6]
from the lift arm by-pass valve to the drive motor case
drain. Disconnect the wire harness tie-strap mounts (Item 1)
[Figure 20-43-8] from the lift arm by-pass bracket.
Remove the lift arm by-pass tubeline (Item 3) [Figure
20-43-6] from the control valve drain.

T190 Bobcat Loader


20-43-3 Service Manual
Figure 20-43-9 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Removal And Installation (Cont'd)

Figure 20-43-10

P-51983

Disconnect the connectors (Item 1) [Figure 20-43-9]


from the lift and tilt actuators.
P-51721

Remove the two lift arm by-pass valve mounting bolts


(Item 1) [Figure 20-43-10].

Remove the lift arm by-pass valve and mounting bracket.

Figure 20-43-11

P-51727

Remove tubeline clamp bolt (Item 1) [Figure 20-43-11]


from the auxiliary tubelines in the left rear upright.

Installation: Tighten bolt to 15-20 ft.-lbs. (20-27 Nm)


torque.

T190 Bobcat Loader


20-43-4 Service Manual
Figure 20-43-12 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Removal And Installation (Cont'd)

Figure 20-43-14
2 1
1

P-51980

1
Remove and cap both tubelines (Item 1) [Figure 20-43-
12] from the auxiliary section of the control valve.
P-51728
Disconnect and cap the drain hose (Item 2) [Figure 20-
43-12] from the control valve.
Remove the fixed-end main valve hose (Item 1) [Figure
Figure 20-43-13 20-43-14] from the main control valve fitting.

Figure 20-43-15

2
1

3 1

P-51982

P-51722
Disconnect and cap the tubelines (Item 1) and (Item 2)
[Figure 20-43-13] from the tilt section of the control
valve. Mark and disconnect the BICS™ electric solenoid
connector (Item 1) [Figure 20-43-15].
Disconnect and cap the tubeline (Item 3) [Figure 20-43-
13] from the lift section of the control valve.

T190 Bobcat Loader


20-43-5 Service Manual
Figure 20-43-16 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Actuator Removal And Installation (Out of Loader)

1 Remove the control valve from the loader.


1
Figure 20-43-18

P-51726

1
Connect a hoist to the lifting brackets (Item 1) [Figure 20-
43-16] on the control valve.

Figure 20-43-17
P-51732

Remove the two mount bolts (Item 1) [Figure 20-43-18]


from the tilt actuator.
1 P-26095A
1
Installation: Tighten the mounting bolts to 90-100 in.-lbs.
(10,2-11,3 Nm) torque.

Figure 20-43-19

1P-51713
P-26062A P-51713
P-51713

Remove the two mounting bolts (Item 1) [Figure 20-43- 1


17] fastening the control valve and bracket to the side of
the loader.

Remove the control valve from the loader [Figure 20-43-


17].

Reverse procedure for installation. P-51733

Slide the actuator mount bracket (Item 1) [Figure 20-43-


19] away from the control valve.

Pull the actuator away from the control valve [Figure 20-
43-19].

T190 Bobcat Loader


20-43-6 Service Manual
Figure 20-43-20 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Actuator Removal And Installation (Out of Loader)


(Cont’d)

Figure 20-43-22

1
1

P-51734

Using a drift pin and a hammer, remove the actuator


linkage pin (Item 1) [Figure 20-43-20] from the actuator 1
and the tilt spool.
P-51737
Remove the actuator and linkage pin from the valve.

Figure 20-43-21 Remove the two mount bolts (Item 1) [Figure 20-43-22]
from the lift actuator.

Installation: Tighten the mounting bolts to 90-100 in.-lbs.


(10,2-11,3 Nm) torque.

Figure 20-43-23
1

1
2

P-51736

Inspect the O-ring (Item 1) [Figure 20-43-21] on the face


of the actuator, and replace as needed.

Check the linkage pin (Item 2) [Figure 20-43-21] and P-51799


replace as needed.

Slide the actuator mount bracket (Item 1) [Figure 20-43-


23] away from the control valve.

Pull the actuator away from the control valve [Figure 20-
43-23].

T190 Bobcat Loader


20-43-7 Service Manual
Figure 20-43-24 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Actuator Removal And Installation (Out of Loader)


(Cont’d)

Figure 20-43-26

P-51800

1 2
Using a drift pin and a hammer, remove the actuator
linkage pin (Item 1) [Figure 20-43-24] from the actuator
and the tilt spool. 3
P-51738
Remove the actuator and linkage pin from the valve.

Figure 20-43-25 NOTE: The two longer bolts (Item 1) are used to
mount the lift actuator and end cap (Item 2)
[Figure 20-43-26] to the control valve.
The two shorter mount bolts (Item 3) are used
to mount the tilt actuator to the end cap (Item
4) [Figure 20-43-26].
1
Installation: Tighten the mounting bolts to 90-100 in.-lbs.
(10,2-11,3 Nm) torque (Item 1) [Figure 20-43-26]

P-51736

Inspect the O-ring (Item 1) [Figure 20-43-25] on the face


of the actuator, and replace as needed.

Check the linkage pin (Item 2) [Figure 20-43-25] and


replace as needed.

T190 Bobcat Loader


20-43-8 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Identification Chart (ACS)
Figure 20-43-27

J2 C3
C2
J4
D5 B3
E3
E3
G1 G2

F2 A3 D3
B2
D4 E2
A2

D1
D2
A1
E1
F1 H2 B1
H3
MR C1
H1 J3
J1
MS1929

ITEM T190 LOADER ITEM T190 LOADER


A1 Lift Cylinder Base End E1 Lift Spool Centering Spring
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 LIft Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End G1 Auxiliary Solenoid Stem
C1 Load Check/BICS™ Valve G2 Auxiliary Solenoid Stem
Lift H1 BICS™ Valve Solenoid
C2 Load Check Valve Tilt Function
H2 BICS™ Lock Valve (Tilt)
C3 Load Check Valve Auxiliary Function
D1 Anti-Cavitation Valve H3 BICS™ Lock Valve (Lift)
Lift (Rod End) J1 Inlet Fluid Flow (From Pump)
D2 Port Relief/Anti-Cavitation Valve – 3500 PSI J2 Outlet Fluid Flow (Return to Tank)
Lift (Base End) J3 Lift Arm By-Pass Orifice
D3 Port Relief/Anti-Cavitation Valve – 3500 PSI J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 3300 PSI
D4 Port Relief/Anti-Cavitation Valve – 3500 PSI
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)

T190 Bobcat Loader


20-43-9 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) BICS™ Valve, Lift Load Check Valve Removal And
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Installation

Mount Bracket Removal and Installation Figure 20-43-30

Figure 20-43-28

1 P-51740

P-51730
Remove the lift load check valve (Item 1) [Figure 20-43-
30].
Remove the control valve and mount bracket (Item 1)
[Figure 20-43-28] from the loader. Installation: Lubricate the o-ring and tighten the valve to
55-65 ft.-lbs. (75-88 Nm) torque.
Figure 20-43-29
Figure 20-43-31

P-51731

P-51439

Disconnect the tubeline (Item 1) [Figure 20-43-29] from


the inlet fitting on the control valve. Remove and install new O-rings (Item 1) and back-up
ring (Item 2) [Figure 20-43-31].
Remove the two mount bolts (Item 2) [Figure 20-43-29]
from the control valve mount plate. Remove the mount
plate and tubeline.

T190 Bobcat Loader


20-43-10 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-34
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

BICS™ Valve, Lift Load Check Valve Removal And


Installation (Cont’d)
4
Figure 20-43-32

1 1
3
2

P-51453

Remove the spring (Item 1) and poppet (Item 2) [Figure


20-43-34].

P-51440 Check the orifice (Item 3) [Figure 20-43-34] in the


poppet to be sure it is not plugged.
Check for free movement of the load check valve (Item 1) Installation: Install a new O-ring (Item 4) [Figure 20-43-
[Figure 20-43-32]. 34] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lbs. (52-61 Nm)
Load Check Valve Removal And Installation (Tilt & torque.
Auxiliary)

Figure 20-43-33

P-51741

At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-43-33].

At the front side of the control valve locate the auxiliary


section load check valve (Item 2) [Figure 20-43-33].

NOTE: The tilt and auxiliary load check valves are


interchangeable.

T190 Bobcat Loader


20-43-11 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-37
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Anti-Cavitation Valve (Lift, Rod End)


4
Figure 20-43-35

1
3
2

P-51453
1

Remove the spring (Item 1) and poppet (Item 2) [Figure


20-43-37].
P-51742
Check the orifice (Item 3) [Figure 20-43-37] in the
poppet to be sure it is not plugged.
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-43-35]. Installation: Install a new O-ring (Item 4) [Figure 20-43-
37] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38-45 ft.-lbs. (52-61 Nm)
torque.

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

Figure 20-43-36

P-51452

Always use new O-ring (Item 1) [Figure 20-43-36] on the


anti-cavitation valve plug.

T190 Bobcat Loader


20-43-12 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Tilt, Base End)
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-43-40
Port Relief/Anti-Cavitation Valve (Lift, Base End)

Figure 20-43-38

1
P-51742

P-51742 Remove the tilt port relief/anti cavitation valve (Item 1)


[Figure 20-43-40] from the base end of the tilt section.
Loosen the lift circuit port relief/anti cavitation valve (Item Figure 20-43-41
1) [Figure 20-43-38].

Figure 20-43-39

1 P-51454

P-51451 Replace the O-ring (Item 1) [Figure 20-43-41] before


installation.

Replace the O-ring (Item 1) [Figure 20-43-39] before Installation: Lightly lubricate with oil and tighten to 38-45
installation. ft.-lbs. (52-61 Nm) torque.

Installation: Lightly lubricate with oil and tighten to 38-45


ft.-lbs. (52-61 Nm) torque.

T190 Bobcat Loader


20-43-13 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief Valve
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-43-44
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)

Figure 20-43-42

P-51742

P-51742 Remove the port relief plug (Item 1) [Figure 20-43-44]


from the auxiliary circuit of the control valve.
Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-43-45
[Figure 20-43-42] from the rod end of the tilt section.

Figure 20-43-43

1 P-51801

P-51455 Installation: Always use new O-rings (Item 1) [Figure


20-43-45]. Lightly lubricate with oil and tighten to 38-45
ft.-lbs. (52-61 Nm) torque.
Replace the O-ring (Item 1) [Figure 20-43-43] before
installation.

Installation: Lightly lubricate with oil and tighten to 38-45


ft.-lbs. (52-61 Nm) torque.

T190 Bobcat Loader


20-43-14 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Plug Removal
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-43-48
Port Relief Valve (Cont’d)

Figure 20-43-46

1
1

P-51459

P-51743 At the top side of the control valve, remove the plug (Item
1) [Figure 20-43-48].
The control valve may be equipped with an optional Figure 20-43-49
auxiliary port relief valve (Item 1) [Figure 20-43-46].

Remove the auxiliary port relief valve.

Figure 20-43-47

1
P-51460

Installation: Always use new O-rings (Item 1) [Figure


20-43-49]. Tighten to 40 ft.-lbs. (54 Nm) torque.
P-51640

Installation: Always use new O-rings (Item 1) [Figure


20-43-47]. Lightly lubricate with oil and tighten to 38-45
ft.-lbs. (52-61 Nm) torque.

T190 Bobcat Loader


20-43-15 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) End Cap Block Removal and Installation
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Remove the lift and tilt actuators from the control valve.
Plug Removal (Cont’d) (See Actuator Removal And Installation (Out of Loader)
on Page 20-43-6.)
Figure 20-43-50
Figure 20-43-52

1
P-51461 2
P-51744

At the bottom side of the control valve remove the plug


(Item 1) [Figure 20-43-50]. Disconnect the tube line (Item 1) [Figure 20-43-52] from
the end cap block.
Figure 20-43-51
Remove the two end cap block mount screws (Item 2)
[Figure 20-43-52].

Installation: Tighten the screws to 90-100 in.-lbs. (10-


11,3 Nm) torque.

Figure 20-43-53
1

P-51462 1

Installation: Always use new O-rings (Item 1) [Figure


20-43-51]. Tighten to 40 ft.-lbs. (54 Nm) torque.

P-51745

Remove the end cap block (Item 1) [Figure 20-43-53]


from the control valve.

T190 Bobcat Loader


20-43-16 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-56
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Lift Spool Removal and Installation

The tool listed will be needed to do the following 1


procedure:

MEL 1285 - Spring Tool

Remove the end cap block from the control valve.

Figure 20-43-54

1
P-51748

Remove the two screws (Item 1) [Figure 20-43-56] from


the lift spool end cap.
1
Installation: Lubricate the screws and tighten to 90-100
in.-lbs. (10-11,3 Nm) torque.

Figure 20-43-57

P-51746

Remove the O-ring (Item 1) [Figure 20-43-54].

Installation: Replace the O-ring, and lubricate lightly


with oil before installation of the end cap block.

Figure 20-43-55 1

P-51749

Remove the lift spool end cap (Item 1) [Figure 20-43-57]


2 from the control valve.
1

P-51747

Remove the spacer (Item 1) and O-ring (Item 2) [Figure


20-43-55] from the lift spool.

T190 Bobcat Loader


20-43-17 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-60
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Lift Spool Removal and Installation (Cont'd)

Figure 20-43-58

P-51772

1 Clamp the linkage end of the spool in a vise [Figure 20-


43-60].
P-51770
NOTE: Protect spool before clamping in vise.
Remove the lift spool assembly and seal (Item 1) [Figure Figure 20-43-61
20-43-58] from the control valve.

Figure 20-43-59

1
P-51773

P-51771 Install the spring tool (Item 1) [Figure 20-43-61] over the
centering spring.

Remove the lift spool seal (Item 1) [Figure 20-43-59]


from the linkage end of the valve.

T190 Bobcat Loader


20-43-18 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-64
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Lift Spool Removal and Installation (Cont'd)


2
1
Figure 20-43-62

P-51771 P-51775

Remove the spool seal(s) (Item 1) and the back-up


washer (Item 2) [Figure 20-43-64].
N-190146
Assembly: Always use a new spool seal.
Remove the bolt (Item 1) [Figure 20-43-62] holding the Figure 20-43-65
centering spring to the spool.

Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3


Nm) torque. 1

Remove spring tool from the spring assembly.

Figure 20-43-63

2
3
3 3

1 P-51749
4

Install the lift spool assembly (Item 1) [Figure 20-43-65]


in the spool bore.

Install the end cap (Item 2) [Figure 20-43-65].

P-51776 Install the mounting screws (Item 3) [Figure 20-43-65].

Installation: Lubricate the screws and tighten to 90-100


Inspect the adapter (Item 1), collar (Item 2), spring (Item in.-lbs. (10-11,3 Nm) torque.
3) and washer (Item 4) [Figure 20-43-63].

T190 Bobcat Loader


20-43-19 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-68
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Lift Spool Removal and Installation (Cont'd)

Figure 20-43-66

P-51746

Install the O-ring (Item 1) [Figure 20-43-68] on the


control valve.
P-51777
Figure 20-43-69
Install the spool seal (Item 1) [Figure 20-43-66] on the
linkage end of the valve.

Figure 20-43-67

3
2

1 1
2
P-51744

2
Install the end cap block (Item 1) and the two mount bolts
(Item 2) [Figure 20-43-69].
P-51747
Installation: Tighten the screws to 90-100 in.-lbs. (10-
11,3 Nm) torque.
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-43-67] on the lift spool. Connect the tube line (Item 3) [Figure 20-43-69] to the
end cap block.

Install the lift and tilt actuators to the control valve.

T190 Bobcat Loader


20-43-20 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-72
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Tilt Spool Removal and Installation

Remove the end cap block. (See End Cap Block


Removal and Installation on Page 20-43-16.)

Figure 20-43-70 2

P-51780

Remove the spool centering block (Item 1) [Figure 20-


2 43-72] from the control valve.
1
Check and replace the O-ring (Item 2) [Figure 20-43-72]
before replacing the spool centering block.
P-51778
Figure 20-43-73
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-43-70] from the tilt spool.

Figure 20-43-71

2
P-51781

Remove the tilt spool, centering spring, back-up washer


2 and spool seal (Item 1) [Figure 20-43-73].
P-51779
Assembly: Always use a new spool seal.

Disconnect the tubeline (Item 1) [Figure 20-43-71].

Remove the three screws (Item 2) [Figure 20-43-71]


from the spool centering block.

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


Nm) torque.

T190 Bobcat Loader


20-43-21 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-76
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Tilt Spool Removal And Installation (Cont'd)


2 1
Figure 20-43-74
3

4
1

N-18944A

Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-43-76].
N-18942
Figure 20-43-77
Put the linkage end of the spool in the vice [Figure 20-
43-74]. 2
1
Install the spring tool (Item 1) [Figure 20-43-74] over the
centering spring.

Figure 20-43-75

1
1

P-51545 N-18943

Remove the spool seal(s) (Item 1) and the back-up


washer (Item 2) [Figure 20-43-77].

Assembly: Always use a new spool seal.

N-19014

Remove the bolt (Item 1) [Figure 20-43-75] holding the


centering spring to the spool.

Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3


Nm) torque.

Remove spring tool from the spring assembly.

T190 Bobcat Loader


20-43-22 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-80
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

Auxiliary Spool Removal And Installation

Figure 20-43-78

1 1

2
P-51783

Remove the spacer (Item 1) and O-ring (Item 2) [Figure


20-43-80] from the auxiliary spool.
2 P-51779
Figure 20-43-81
Disconnect the tubeline (Item 1) [Figure 20-43-78] from
the spool centering block.

Remove the three screws (Item 2) [Figure 20-43-78]


from the spool centering block.

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


Nm) torque.
1
Remove the spool centering block from the control valve.

Figure 20-43-79 2

P-51784

Remove the spring (Item 1) and center spring retainer


(Item 2) [Figure 20-43-81] from the auxiliary spool.

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


20-43-81] must be replaced, replace the
retainer on the opposite end also.
2

1
P-51782

Remove the spring (Item 1) and center spring retainer


(Item 2) [Figure 20-43-79] from the auxiliary spool.

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


20-43-79] must be replaced, replace the
retainer on the opposite end also.

T190 Bobcat Loader


20-43-23 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Auxiliary Solenoid Disassembly and Assembly
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-43-84
Auxiliary Spool Removal And Installation (Cont’d)

Figure 20-43-82

1
2
P-51552

P-51785 Remove the nut (Item 1) [Figure 20-43-84] from both


solenoids.
Remove the spacer (Item 1) and O-ring (Item 2) [Figure Installation: Tighten the nut to 48-72 in.-lbs. (5-8 Nm)
20-43-82] from the auxiliary spool. torque.
Figure 20-43-83 Figure 20-43-85

P-51786
P-51553

Remove the auxiliary spool (Item 1) [Figure 20-43-83]. Remove the nut (Item 1) and solenoid coil (Item 2)
[Figure 20-43-85].

Use an Ohm meter to measure the solenoid coil


resistance.

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

T190 Bobcat Loader


20-43-24 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) BICS™ Valve Solenoid Disassembly And Assembly
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-43-88
Auxiliary Solenoid Disassembly and Assembly
(Cont’d)

Figure 20-43-86
1

1
2

P-51788

Remove the nut (Item 1) [Figure 20-43-88] from the


P-51787 solenoid stem.

Installation: Tighten the nut to 53 in.-lbs. (6 Nm) torque.


Remove the solenoid stem (Item 1) [Figure 20-43-86].
Remove the solenoid coil (Item 2) [Figure 20-43-88].
Installation: Tighten the stem to 10-14 ft.-lbs. (14-19
Nm) torque. Figure 20-43-89
Figure 20-43-87
1

2
N-18693A

P-51555
Remove the O-rings (Item 1) [Figure 20-43-89] from
both ends of the solenoid coil.
Remove the O-rings (Item 1) [Figure 20-43-87] from the
solenoid stem. Use an Ohm meter to measure the solenoid coil
resistance.
Check and clean the screen (Item 2) [Figure 20-43-87].
The correct resistance for the coil is 9.79 ± .29 Ohms.

T190 Bobcat Loader


20-43-25 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Use only new O-rings and apply oil to all O-rings and
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) back-up rings before installation.

BICS™ Valve Solenoid Disassembly And Assembly Install new O-rings (Item 1) [Figure 20-43-89] & [Figure
(Cont’d) 20-43-91] and new back-up rings (Item 2) [Figure 20-43-
91] on the solenoid stem.
Figure 20-43-90
BICS™ Valve, Lock Valve Removal And Installation

Figure 20-43-92

1
2
1

P-51789

Remove the solenoid stem (Item 1) [Figure 20-43-90]. P-51790

Installation: Lubricate the O-rings and tighten the stem


to 20-24 ft.-lbs. (27-33 Nm) torque. Locate the two BICS™ lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-43-92] is for the lift circuit.
Figure 20-43-91
Figure 20-43-93

3
2

1
1

N-18694
P-51791

Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-43-91] from the stem. Remove the lift lock valve (Item 1) [Figure 20-43-93]
from the back of the control valve.
Clean all parts in solvent and dry with compressed air.
Installation: Lightly lubricate the lock valve o-rings and
Inspect all parts for wear and replace any showing tighten to 20-24 ft.-lbs. (27-33 Nm) torque.
excessive wear.

NOTE: The screen (Item 3) [Figure 20-43-91] may be


cleaned with solvent. If it is torn or worn it
needs to be replaced.

T190 Bobcat Loader


20-43-26 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-96
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

BICS™ Valve, Lock Valve Removal And Installation


(Cont’d)
1
Figure 20-43-94
1
1

1 1

1 2
1 2
2
P-51564
1
2
Remove the O-rings (Item 1) and back-up rings (Item 2)
2 [Figure 20-43-96] from the tilt lock valve, and replace
2 with new.
P-51564

Remove the O-rings (Item 1) and back-up rings (Item 2)


[Figure 20-43-94] from the lift lock valve, and replace
with new.

Figure 20-43-95

P-51792

Remove the tilt lock valve (Item 1) [Figure 20-43-95]


from the back of the control valve.

Installation: Lightly lubricate the lock valve o-rings and


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

T190 Bobcat Loader


20-43-27 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Figure 20-43-99
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)

BICS™ Valve, Check Valve Removal And Installation 1

Figure 20-43-97

4
P-51447
1

Check that there is no blockage in the orifice (Item 1)


[Figure 20-43-99].
P-51788
Inspect the check valve (Item 2) and spring (Item 3)
[Figure 20-43-99].
Remove the BICS™ valve (Item 1) [Figure 20-43-97].
Replace the O-ring (Item 4) [Figure 20-43-99] on the
Installation: Lubricate the o-ring and tighten the valve to plug before installation.
55-65 ft.-lbs. (75-88 Nm) torque.

Figure 20-43-98

P-51446

Remove the plug (Item 1) [Figure 20-43-98] from the top


of the BICS™ valve.

T190 Bobcat Loader


20-43-28 Service Manual
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Main Relief Valve
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-43-102
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly
And Assembly

Figure 20-43-100

1
P-51794

Remove the main relief valve (Item 1) [Figure 20-43-


P-51793 102].

Figure 20-43-103
Remove the fitting (Item 1) [Figure 20-43-100] from the
valve.

Figure 20-43-101

1
1
P-51463

Remove the O-rings from the main relief valve (Item 1)


P-51437 [Figure 20-43-103].

Installation: Always use new O-rings. Tighten to 38-45


Check the lift arm by-pass orifice (Item 1) [Figure 20-43- ft.-lbs. (52-61 Nm) torque.
101].

NOTE: This orifice is not removable from the valve


casting.

T190 Bobcat Loader


20-43-29 Service Manual
LIFT ARM BY-PASS CONTROL VALVE Figure 20-50-1

Inspecting

Raise the lift arms 6 feet (2 m) off the ground. Stop the 2
engine. Turn the Lift Arm By-Pass Control Knob
clockwise 1/4 turn. Then pull the Lift Arm By-Pass
Control Knob until the lift arms slowly lower. 4
3
Removal and Installation

1
P-31990A

The Lift Arm By-Pass valve (Item 1) [Figure 20-50-1] is


located under the right side of the control panel.

Hold the Lift Arm By-Pass Control knob (Item 2) and


loosen the jam nut (Item 3) on the Lift Arm By-Pass valve
WARNING shaft [Figure 20-50-1].

Never work on a machine with the lift arms up unless Remove the Lift Arm By-Pass Control knob (Item 2) and
the lift arms are secured by an approved lift arm the jam nut (Item 3) from the Lift Arm By-Pass valve shaft
support device. Failure to use an approved lift arm [Figure 20-50-1].
support device can allow the lift arms or attachment
to fall and cause injury or death. Remove the rubber washer (Item 4) [Figure 20-50-1].
W-2059-0598

Install jack stands under the rear corners of the loader.

Start the engine. Raise the lift arms and install an


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

Raise the operator cab.(See Raising The Operator Cab


on Page 10-30-1.)

T190 Bobcat Loader


20-50-1 Service Manual
LIFT ARM BY-PASS CONTROL VALVE (CONT'D) Disassembly And Assembly

Removal And Installation (Cont’d) Figure 20-50-3

Figure 20-50-2
1

1
4

2
3 P-26065A

P-48894
Remove the by-pass valve (Item 1) [Figure 20-50-3]
from the valve block. Inspect the by-pass valve for
Disconnect the base end lift tubeline (Item 1) [Figure 20- damage and replace if necessary.
50-2] from the Lift Arm By-Pass valve.
Installation: Tighten the valve to 33-37 ft.-lbs. (45-50
Disconnect the drain hose (Item 2) [Figure 20-50-2] from Nm) torque.
the Lift Arm By-Pass valve.
Inspect the hydraulic fittings on the valve block for
Disconnect the motor case drain hose (Item 3) [Figure damage and replace if necessary.
20-50-2].

Remove the two mounting bolt/nuts (Item 4) [Figure 20-


50-2].

Installation: Tighten the mounting bolts to 180-200 in.


lbs. (21-23 Nm) torque.

Remove the lift arm by-pass control valve.

T190 Bobcat Loader


20-50-2 Service Manual
HYDRAULIC PUMP Figure 20-60-1

Check The Output Of The Hydraulic Pump Without


Power Bob-Tach

WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
1
P-26071

WARNING Disconnect the OUTLET hose (Item 1) [Figure 20-60-1]


from the pump.
Never work on a machine with the lift arms up unless
Figure 20-60-2
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

The tools listed will be needed to do the following


2 1
procedure:

MEL1563 - Remote Start Tool


MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit

Lift and block the loader. (See Procedure on Page 10-10-


1.) P-48256

Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page Connect the INLET hose (Item 1) [Figure 20-60-2] from
10-20-1.) the tester to the OUTLET fitting (Item 2) [Figure 20-60-1]
of the pump. Connect the OUTLET hose (Item 2) [Figure
Raise the operator cab. (See Raising The Operator Cab 20-60-2] from the tester to the hose (Item 1) [Figure 20-
on Page 10-30-1.) 60-1] which was disconnected from the pump.

Open the rear door of the loader.

Connect the remote start tool. (See Procedure on Page


10-60-1.)
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

T190 Bobcat Loader


20-60-1 Service Manual
HYDRAULIC PUMP (CONT'D)

Check The Output Of The Hydraulic Pump Without


Power Bob-Tach (Cont'd)

Figure 20-60-3
EXAMPLE: TESTER
CONNECTION
Reservoir

Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277

Sample tester connection shown [Figure 20-60-3].

Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.

Warm the fluid to 140°F. (60°C.) by turning the restrictor


control (Item 1) [Figure 20-60-3] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM.

Push the maximum/variable flow switch (on the remote


start tool) to engage the front auxiliary hydraulics. The
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least
80% of free flow.

HIGH PRESSURE FLOW (GPM)


%= X100
FREE FLOW (GPM)

A low percentage may indicate a failed pump.

*Refer to SPECIFICATIONS Section, Contents Page


SPEC-01 for system relief pressure and full RPM.

T190 Bobcat Loader


20-60-2 Service Manual
HYDRAULIC PUMP (CONT'D) Figure 20-60-5

Check The Output Of The Hydraulic Pump With


Power Bob-Tach.

WARNING 2 1

Put jackstands under the front axles and rear corners


of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

P-48256
Figure 20-60-4

Connect the INLET hose (Item 1) [Figure 20-60-5] from


the tester to the OUTLET fitting (Item 2) [Figure 20-60-4]
on the top of the Power Bob-Tach block. Connect the
1 OUTLET hose (Item 2) [Figure 20-60-5] from the tester
to the hose (Item 1) [Figure 20-60-4] which was
2
disconnected from the Power Bob-Tach block.

IMPORTANT
The hydraulic tester must be in the fully open
P-48255 position before you start the engine.
I-2024-0284

The tools listed will be needed to do the following


procedure:

MEL1563 - Remote Start Tool


MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit

Lift and block the loader. (See Procedure on Page 10-10-


1.)

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

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Open the rear door of the loader.

Connect the remote start tool. (See Procedure on Page


10-60-1.)

Disconnect the OUTLET hose (Item 1) [Figure 20-60-4]


from the top of the Power Bob-Tach block.

T190 Bobcat Loader


20-60-3 Service Manual
HYDRAULIC PUMP (CONT'D)

Check The Output Of The Hydraulic Pump With


Power Bob-Tach. (Cont'd)

Figure 20-60-6
EXAMPLE: TESTER
CONNECTION
Reservoir

Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277

Sample tester connection shown [Figure 20-60-6].

Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.

Warm the fluid to 140°F. (60°C.) by turning the restrictor


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

Push the maximum/variable flow switch (on the remote


start tool) to engage the front auxiliary hydraulics. The
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least
80% of free flow.

HIGH PRESSURE FLOW (GPM)


%= X100
FREE FLOW (GPM)

A low percentage may indicate a failed pump.

*Refer to SPECIFICATIONS Section, Contents Page


SPEC-01 for system relief pressure and full RPM.

T190 Bobcat Loader


20-60-4 Service Manual
HYDRAULIC PUMP (CONT'D) Disconnect and cap the outlet hose (Item 1) [Figure 20-
60-7] from the back of the hydraulic pump.
Removal And Installation

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

Figure 20-60-7

P-26071

Lift and block the rear of the loader. (See Installing Lift
Arm Support Device on Page 10-20-1.)

Raise the lift arms and install an approved lift arm support
device. (See Procedure on Page 10-10-1.)

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Drain the hydraulic fluid from the reservoir. (See


Replacing Hydraulic Fluid on Page 10-120-2.)

Open the rear door of the loader.


Remove the Power Bob-Tach block if equipped. (See
Removal And Installation on Page 20-120-1.)
T190 Bobcat Loader
20-60-5 Service Manual
HYDRAULIC PUMP (CONT'D)

WARNING Removal And Installation (Cont’d)

Figure 20-60-10
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

P-26347
Figure 20-60-8

1 2

P-26347

Remove the O-ring (Item 1) [Figure 20-60-10].

Remove the coupler (Item 2) [Figure 20-60-10] from the


hydraulic pump shaft.
1
Reverse the removal procedure to install the hydraulic
P-26068
pump.

Disconnect and cap the inlet hose (Item 1) [Figure 20- Installation: Use a new O-ring (Item 1) [Figure 20-60-10]
60-8] from the front of the hydraulic pump. when installing the hydraulic pump. (See Disassembly
And Assembly on Page 20-60-8.)
Figure 20-60-9

P-26069

Remove the two mounting bolts (Item 1) [Figure 20-60-


9] from the hydraulic pump.

Installation: Tighten the mounting bolts to 27-37 ft.-lbs.


(37-50 Nm) torque.

Remove the hydraulic pump (Item 2) [Figure 20-60-9]


from the hydrostatic pump.

T190 Bobcat Loader


20-60-6 Service Manual
HYDRAULIC PUMP (CONT'D)

Identification

15

8
7
6
14

12 13
11

10
9 1. Retaining Ring
7
1 4 5 2. Pump End Section
3 3. Pre-Load Seal
4. Load Seal
2 5. Section Seal
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
10. Pump Center Section
11. Wear Plate
12. Section Seal
13. Pump End Section
14. Bolt (4)
15. Bolt (4)

B-16050A

T190 Bobcat Loader


20-60-7 Service Manual
HYDRAULIC PUMP (CONT'D) Figure 20-60-12

Disassembly And Assembly


1
Figure 20-60-11

P-26352
2

2
P-26353
1

Remove the pump end section (Item 1) [Figure 20-60-


P-26351 12].

Mark the pump sections for correct assembly [Figure 20-


60-11].

Remove the four smaller pump housing bolts (Item 1)


[Figure 20-60-11].

Remove the four larger pump housing bolts (Item 2)


[Figure 20-60-11].

Installation: Tighten the four smaller bolts (Item 1)


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

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

T190 Bobcat Loader


20-60-8 Service Manual
HYDRAULIC PUMP (CONT'D) Figure 20-60-15

Disassembly And Assembly (Cont'd)

Figure 20-60-13 1

P-26358

2
Figure 20-60-16
P-26354

1
Figure 20-60-14

4
3

1
P-26359

2 Remove the pump center section (Item 1) [Figure 20-60-


P-26355 15] & [Figure 20-60-16] from the pump end section.

NOTE: Inspect the pump center section (Item 1)


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

NOTE: Position wear plate (Item 1) [Figure 20-60-14]


inlets and traps as shown with bronze side
toward gears.

NOTE: Inspect the pump end section (Item 3) [Figure


20-60-14] and bushings (Item 4) [Figure 20-60-
14]. If excessive wear or damage is visible, the
pump must be replaced.

T190 Bobcat Loader


20-60-9 Service Manual
HYDRAULIC PUMP (CONT'D) Figure 20-60-19

Disassembly And Assembly (Cont'd)

Figure 20-60-17

1
P-26391

Figure 20-60-20
P-26389

Figure 20-60-18

P-26362

1
1

P-26362

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


P-26390 the pump end section, locate and remove the retaining
ring (Item 1) [Figure 20-60-20] from the spline end of the
drive gear.
Remove the idler gear (Item 1) [Figure 20-60-17] &
[Figure 20-60-18].

NOTE: Inspect the idler gear (Item 1) [Figure 20-60-


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

T190 Bobcat Loader


20-60-10 Service Manual
HYDRAULIC PUMP (CONT'D) Figure 20-60-23

Disassembly And Assembly (Cont'd)

Figure 20-60-21

P-26394

NOTE: Position wear plate (Item 1) [Figure 20-60-23]


P-26392 inlets and traps as shown with bronze side
toward gears.

Remove the drive gear (Item 1) [Figure 20-60-21] from Figure 20-60-24
the pump end section.

NOTE: Inspect the drive gear (Item 1) [Figure 20-60- 1


21]. If excessive wear or damage is visible, the
pump must be replaced.
P-26396
Figure 20-60-22
1

1 P-26395

Remove the load seal (Item 1) [Figure 20-60-24].


2

P-26393

Remove the wear plate (Item 1) [Figure 20-60-22] &


[Figure 20-60-23] and section seal (Item 2) [Figure 20-
60-22] & [Figure 20-60-23] from the pump end section.

T190 Bobcat Loader


20-60-11 Service Manual
HYDRAULIC PUMP (CONT'D)

Disassembly And Assembly (Cont'd)

Figure 20-60-25

P-26398

P-26397

Remove the pre-load seal (Item 1) [Figure 20-60-25].

Figure 20-60-26

P-26374

NOTE: Inspect the pump end section (Item 1) [Figure


20-60-26] and bushings (Item 2) [Figure 20-60-
26] . If excessive wear or damage is visible,
the pump must be replaced.

T190 Bobcat Loader


20-60-12 Service Manual
HYDRAULIC PUMP (HIGH FLOW) Figure 20-61-1

Check The Output Of The Hydraulic Pump (Standard)

2
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

1
P-26753

WARNING Disconnect the OUTLET hose (Item 1) [Figure 20-61-1]


from the pump.
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
Figure 20-61-2
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

2
IMPORTANT 1

The hydraulic tester must be in the fully open


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

The tools listed will be needed to do the following P-48256


procedure:

MEL1563 - Remote Start Tool Connect the INLET hose (Item 1) [Figure 20-61-2] from
MEL10103 - Hydraulic Tester the tester to the OUTLET fitting (Item 2) [Figure 20-61-1]
MEL10106 - Hydraulic Test Kit of the pump. Connect the OUTLET hose (Item 2) [Figure
20-61-2] from the tester to the hose (Item 1) [Figure 20-
Lift and block the loader. (See Procedure on Page 10-10- 61-1] which was disconnected from the pump.
1.)

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

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Open the rear door of the loader.

Connect the remote start tool. (See Procedure on Page


10-60-1.)

T190 Bobcat Loader


20-61-1 Service Manual
HYDRAULIC PUMP (HIGH FLOW)) (CONT'D)

Check The Output Of The Hydraulic Pump (Standard)


(Cont'd)

Figure 20-61-3
EXAMPLE: TESTER
CONNECTION
Reservoir

Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277

Sample tester connection shown [Figure 20-61-3].

Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.

Warm the fluid to 140°F. (60°C.) by turning the restrictor


control (Item 1) [Figure 20-61-3] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM.

Push the maximum/variable flow switch (on the remote


start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least
80% of free flow.

%= HIGH PRESSURE FLOW (GPM) X100


FREE FLOW (GPM)

A low percentage may indicate a failed pump.

*Refer to SPECIFICATIONS Contents Page SPEC-01 for


system relief pressure and full RPM.

T190 Bobcat Loader


20-61-2 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-4

Check The Output Of The Hydraulic Pump (High


Flow)

WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

P-48463

WARNING Install a jumper hose (Item 1) [Figure 20-61-4] onto the


front auxiliary quick couplers.
Never work on a machine with the lift arms up unless
Raise the lift arms and install an approved lift arm support
the lift arms are secured by an approved lift arm
device. (See Installing Lift Arm Support Device on Page
support device. Failure to use an approved lift arm
10-20-1.)
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

The tools listed will be needed to do the following


procedure:

MEL1563 - Remote Start Tool


MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit

Lift and block the loader. (See Procedure on Page 10-10-


1.)

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Open the rear door of the loader.

Connect the remote start tool. (See Procedure on Page


10-60-1.)

T190 Bobcat Loader


20-61-3 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-7

Check The Output Of The Hydraulic Pump (High EXAMPLE: TESTER


Flow) (Cont'd) CONNECTION
Reservoir

Figure 20-61-5

Hydraulic Pump
Out In
High Flow Valve

1
1 B-16277

Sample tester connection shown [Figure 20-61-7].


2
P-48235 Start the engine and run at low idle RPM. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
Disconnect the OUTLET hose (Item 1) [Figure 20-61-5] coupler. Make sure the tester is connected correctly. If no
from the High Flow valve. flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
Figure 20-61-6 engine speed to full RPM*.

Warm the fluid to 140°F. (60°C.) by turning the restrictor


control (Item 1) [Figure 20-61-7] on the tester to about
1000 PSI (6895 kPa).

NOTE: DO NOT EXCEED 3300 PSI.


2 1
Open the restrictor control and record the free flow
(GPM) at full RPM. Turn the restrictor control on the
tester to 3300 PSI and the flow should go to zero GPM.

If pressure readings are not obtained go to the High Flow


Valve, relief valve adjustment procedure. (See High Flow
Relief Valve Adjustment Procedure on Page 20-100-3.)
P-48256

Record the highest pressure (PSI) and flow (GPM). The


high pressure flow must be at least 80% of free flow.
Connect the INLET hose (Item 1) [Figure 20-61-6] from
the tester to the OUTLET hose (Item 1) [Figure 20-61-5]
on the High Flow valve. Connect the OUTLET hose (Item %= HIGH PRESSURE FLOW (GPM) X100
2) [Figure 20-61-6] from the tester to the fitting (Item 2) FREE FLOW (GPM)
[Figure 20-61-5] on the High Flow valve.
A low percentage may indicate a failed pump.
Lower the cab.
*Refer to Hydraulic Schematics Legend for system relief
pressure and full RPM.

T190 Bobcat Loader


20-61-4 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

Removal And Installation


WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

Figure 20-61-9
Figure 20-61-8

1
1 1
P-26739

P-26741

Disconnect and cap the inlet hoses (Item 1) [Figure 20-


Raise the lift arms and install an approved lift arm support 61-9] from the front of the hydraulic pump.
device. (See Installing Lift Arm Support Device on Page
10-20-1.)

Lift and block the rear of the loader. (See Procedure on


Page 10-10-1.)

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Drain the hydraulic fluid from the reservoir. (See


Replacing Hydraulic Fluid on Page 10-120-2.)

Open the rear door of the loader.

Remove the Power Bob-Tach block if equipped. (See


Removal And Installation on Page 20-120-1.)

Disconnect and cap the outlet hoses (Item 1) [Figure 20-


61-8] from the back of the hydraulic pump.

T190 Bobcat Loader


20-61-5 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-11

Removal And Installation (Cont’d)

Figure 20-61-10

P-26684

1 2

1
2
P-26684

Remove the O-ring (Item 1) [Figure 20-61-11].


P-26740
Remove the coupler (Item 2) [Figure 20-61-11] from the
hydraulic pump shaft.
Remove the two mounting bolts (Item 1) [Figure 20-61-
10] from the hydraulic pump. Reverse the removal procedure to install the hydraulic
pump.
Installation: Tighten the mounting bolts to 27-37 ft.-lbs.
(37-50 Nm) torque. Installation: Use a new O-ring (Item 1) [Figure 20-61-
11] when installing the hydraulic pump. (See
Remove the hydraulic pump (Item 2) [Figure 20-61-10] Disassembly And Assembly on Page 20-61- 8.)
from the hydrostatic pump.

T190 Bobcat Loader


20-61-6 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

Identification

26

22 23
19

27

24 25
23
18 20 21
16 17
15
7 8
14
13

11 12
1
6 7 9 10
5
3 4

1. Retaining Ring 15. Pre-Load Seal


2. Pump End Section 16. Load Seal
3. Pre-Load Seal 17. Section Seal
4. Load Seal 18. Wear Plate
5. Section Seal 19. Drive Gear
6. Wear Plate 20. Idler Gear
7. Pins 21. Pump Section
8. Drive Gear 22. Wear Plate
9. Idler Gear 23. Pins
10. Pump Section 24. Section Seal
11. Wear Plate 25. Pump End Section
12. Section Seal 26. Bolt (4)
13. Spline Section 27. Bolt (4)
14. Pump Center ection

B-16051A

T190 Bobcat Loader


20-61-7 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

Disassembly And Assembly


IMPORTANT
Figure 20-61-12
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1 I-2003-0888
P-26622

Figure 20-61-13

2
1
2

1 P-26622

Mark the pump sections for correct assembly [Figure 20-


61-12].

Remove the four smaller pump housing bolts (Item 1)


[Figure 20-61-12].
P-26624
Remove the four larger pump housing bolts (Item 2)
[Figure 20-61-12].
Remove the pump end section (Item 1) [Figure 20-61-
Installation: Tighten the four smaller bolts (Item 1) 13].
[Figure 20-61-12] to 30 ft.-lbs. (40,7 Nm) torque. Tighten
the four larger bolts (Item 2) [Figure 20-61-12] to 54 ft.-
lbs. (73,2 Nm) torque.

T190 Bobcat Loader


20-61-8 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-16

Disassembly And Assembly (Cont'd)

Figure 20-61-14

1 1

P-26627

2 Figure 20-61-17
P-26625

Figure 20-61-15

1
3

1 P-26628

Remove the pump section (Item 1) [Figure 20-61-16] &


2
P-26626 [Figure 20-61-17] from the pump center section.

NOTE: Inspect the pumps center section (Item 1)


Remove the wear plate (Item 1) [Figure 20-61-14] & [Figure 20-61-17]. If excessive wear or
[Figure 20-61-15] and section seal (Item 2) [Figure 20- damage is visible, the pump must be
61-14] & [Figure 20-61-15] from the pump end section. replaced.

NOTE: Position wear plate (Item 1) [Figure 20-61-15]


inlets and traps as shown with bronze side
toward gears.

NOTE: Inspect the pump end section (Item 3) [Figure


20-61-15] and bushings (Item 4) [Figure 20-61-
15]. If excessive wear or damage is visible, the
pump must be replaced.

T190 Bobcat Loader


20-61-9 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-20

Disassembly And Assembly (Cont'd)

Figure 20-61-18

P-26631

Figure 20-61-21
P-26629

Remove the idler gear (Item 1) [Figure 20-61-18] &


[Figure 20-61-19].

Figure 20-61-19

P-26632
1
Remove the drive gear (Item 1) [Figure 20-61-20] &
[Figure 20-61-21].

NOTE: Inspect the drive gear (Item 1) [Figure 20-61-


P-26630 21]. If excessive wear or damage is visible, the
pump must be replaced.

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


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

T190 Bobcat Loader


20-61-10 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-24

Disassembly And Assembly (Cont'd)


1
Figure 20-61-22

P-26635

1
1

P-26635

2
Remove the load seal (Item 1) [Figure 20-61-24].
P-26633
Figure 20-61-25

Figure 20-61-23

P-26638

P-26637

P-26634
Remove the pre-load seal (Item 1) [Figure 20-61-25].

Remove the wear plate (Item 1) [Figure 20-61-22] &


[Figure 20-61-23] and section seal (Item 2) [Figure 20-
61-22] & [Figure 20-61-23] from the pump center
section.

NOTE: Position wear plate (Item 1) [Figure 20-61-23]


inlets and traps as shown with bronze side
toward gears.

T190 Bobcat Loader


20-61-11 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-28

Disassembly And Assembly (Cont'd) 3

Figure 20-61-26

2
P-26657

NOTE: Position wear plate (Item 1) [Figure 20-61-28]


P-26654 inlets and traps as shown with bronze side
toward gears.

Remove the pump center section (Item 1) [Figure 20-61- NOTE: Inspect the pump center section (Item 3) and
26] from the pump sections. bushings (Item 4) [Figure 20-61-28]. If
excessive wear or damage is visible, the
Figure 20-61-27 pump must be replaced.

Figure 20-61-29

1
2

P-26655

P-26659
Remove the wear plate (Item 1) [Figure 20-61-27] &
[Figure 20-61-28] and section seal (Item 2) [Figure 20-
61-27] & [Figure 20-61-28] from the pump section. Remove the pump section (Item 1) [Figure 20-61-29]
from the pump end section.

T190 Bobcat Loader


20-61-12 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-32

Disassembly And Assembly (Cont'd)

Figure 20-61-30

P-26662

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


P-26660 32]. If excessive wear or damage is visible, the
pump must be replaced.

NOTE: Inspect the pump section (Item 1) [Figure 20-


61-30]. If excessive wear or damage is visible,
the pump must be replaced.

Figure 20-61-31

P-26661

Remove the idler gear (Item 1) [Figure 20-61-31] &


[Figure 20-61-32].

T190 Bobcat Loader


20-61-13 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-35

Disassembly And Assembly (Cont'd)

Figure 20-61-33

P-26666

Remove the drive gear (Item 1) [Figure 20-61-35] from


P-26663 the pump end section.

NOTE: Inspect the drive gear (Item 1) [Figure 20-61-


Figure 20-61-34 35]. If excessive wear or damage is visible, the
pump must be replaced.

Figure 20-61-36

1
P-26665

1
1

P-26664

To remove the drive gear (Item 1) [Figure 20-61-33] from


P-26674
the pump end section, locate and remove the retaining
ring (Item 1) [Figure 20-61-34] from the spline end of the
drive gear. Remove the spline shaft (Item 1) [Figure 20-61-36] from
the end of the drive gear.

NOTE: Inspect the spline shaft (Item 1) [Figure 20-61-


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

T190 Bobcat Loader


20-61-14 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-39

Disassembly And Assembly (Cont'd)

Figure 20-61-37

P-26670

P-26669

2
Remove the load seal (Item 1) [Figure 20-61-39].
P-26667
Figure 20-61-40

Figure 20-61-38
1

P-26672
1
1

P-26671

P-26668
Remove the pre-load seal (Item 1) [Figure 20-61-40].

Remove the wear plate (Item 1) [Figure 20-61-37] &


[Figure 20-61-38] and section seal (Item 2) [Figure 20-
61-37] & [Figure 20-61-38] from the pump end section.

NOTE: Position wear plate (Item 1) [Figure 20-61-38]


inlets and traps as shown with bronze side
toward gears.

T190 Bobcat Loader


20-61-15 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)

Disassembly And Assembly (Cont'd)

Figure 20-61-41

P-26673

NOTE: Inspect the pump end section (Item 1) [Figure


20-61-41] and bushings (Item 2) [Figure 20-61-
41] . If excessive wear or damage is visible,
the pump must be replaced.

T190 Bobcat Loader


20-61-16 Service Manual
HYDRAULIC PUMP (SJC) Figure 20-62-2

Test The Output Of The Hydraulic Auxiliary Pump

WARNING
2 1
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

Figure 20-62-1 P-48256

Connect the INLET hose (Item 1) [Figure 20-62-2] from


the tester, to the OUTLET hose (Item 1) [Figure 20-62-1]
coming from the gear pump. Connect the OUTLET hose
1 (Item 2) [Figure 20-62-2] from the tester, to the INLET
tubeline (Item 2) [Figure 20-62-1] leading to the control
valve.

IMPORTANT
P-64570 The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
The tools listed will be needed to do the following
procedure:

MEL1563 - Remote Start Tool


MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit

Lift and block the loader. (See Procedure on Page 10-10-


1.)

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

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Open the rear door of the loader.

Connect the remote start tool. (See Procedure on Page


10-60-1.)

Disconnect the OUTLET hose (Item 1) [Figure 20-62-1].

T190 Bobcat Loader


20-62-1 Service Manual
HYDRAULIC PUMP (SJC) (CONT'D) Test The Output Of The Hydraulic Charge Pump

Test The Output Of The Hydraulic Auxiliary Pump


(Cont'd)

Figure 20-62-3
WARNING
EXAMPLE: TESTER Put jackstands under the front axles and rear corners
CONNECTION of the frame before running the engine for service.
Reservoir
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

Figure 20-62-4
Hydraulic Pump
Out In
Hydraulic Control
Valve
1 1
B-16277

Sample tester connection shown [Figure 20-62-3].

Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
2
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
P-64315
RPM*.

Warm the fluid to 140°F. (60°C.) by turning the restrictor The tools listed will be needed to do the following
control (Item 1) [Figure 20-62-3] on the tester to about procedure:
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free MEL1563 - Remote Start Tool
flow (GPM) at full RPM. MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
Push the maximum/variable flow switch (on the remote
start tool) to engage the front auxiliary hydraulics. The Lift and block the loader. (See Procedure on Page 10-10-
light will come ON. Push the button (on the right control 1.)
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI) Raise the lift arms and install an approved lift arm support
and flow (GPM). The high pressure flow must be at least device. (See Installing Lift Arm Support Device on Page
80% of free flow. 10-20-1.)

HIGH PRESSURE FLOW (GPM) Raise the operator cab. (See Raising The Operator Cab
%= X100 on Page 10-30-1.)
FREE FLOW (GPM)
Open the rear door of the loader.
A low percentage may indicate a failed pump.
Connect the remote start tool. (See Procedure on Page
*Refer to SPECIFICATIONS Section, Contents Page
10-60-1.)
SPEC-01 for system relief pressure and full RPM.
Disconnect the charge pump OUTLET hose (Item 1)
from the INLET fitting (Item 2) [Figure 20-62-4] at the
charge filter housing.

T190 Bobcat Loader


20-62-2 Service Manual
HYDRAULIC PUMP (SJC) (CONT'D) Turn the restrictor down to 2000 PSI. DO NOT EXCEED
2000 PSI. The high pressure flow must be at least 80% of
Test The Output Of The Hydraulic Charge Pump free flow.
(Cont’d)
HIGH PRESSURE FLOW (GPM)
Figure 20-62-5 %= X100
FREE FLOW (GPM)

A low percentage may indicate a failed pump.

*Refer to Hydraulic Schematics for pump flow and full


RPM.

2 1

P-48256

Connect the INLET hose (Item 1) [Figure 20-62-5] from


the tester, to the charge pump OUTLET hose (Item 1)
[Figure 20-62-4] coming from the gear pump. Connect
the OUTLET hose (Item 2) [Figure 20-62-5] from the
tester, to the INLET fitting (Item 2) [Figure 20-62-4] at
the charge filter housing.

IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.

Warm the fluid to 140°F. (60°C.) by turning the restrictor


control (Item 1) [Figure 20-62-3] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed 2000 PSI.

Open the restrictor control and record the free flow


(GPM) at full RPM.

T190 Bobcat Loader


20-62-3 Service Manual
HYDRAULIC PUMP (SJC) (CONT'D) Disconnect and cap the outlet hose (Item 1) [Figure 20-
62-6] from the back of the hydraulic pump.
Removal And Installation Remove the Power Bob-Tach block (Item 2) [Figure 20-
62-6] if equipped. (See Removal And Installation on
Page 20-120-1.)

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

Figure 20-62-6

P-64546

Lift and block the rear of the loader. (See Procedure on


Page 10-10-1.)

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

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Drain the hydraulic fluid from the reservoir. (See


Replacing Hydraulic Fluid on Page 10-120-2.)

Open the rear door of the loader.

T190 Bobcat Loader


20-62-4 Service Manual
HYDRAULIC PUMP (SJC) (CONT'D)

WARNING Removal And Installation (Cont’d)

Figure 20-62-9
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
3
Figure 20-62-7 1

1 P-64343

Remove the bracket mounting bolt (Item 1) from the


pump mounting bracket (Item 2) [Figure 20-62-9].
1
Note: The mounting bolt is a special purpose bolt.
Only replace with original Bobcat Parts.
P-64547
Installation: Apply a medium strength threadlocker to
mounting bolt and tighten to 90-100 ft.-lbs. (122-136 Nm)
Disconnect and cap the inlet hoses (Item 1) [Figure 20- torque.
62-7] from the front of the hydraulic pump.
Remove the mounting bracket (Item 2) [Figure 20-62-9].
Figure 20-62-8
Remove the hydraulic pump (Item 3) [Figure 20-62-9]
from the hydrostatic pump.

P-64549

Remove the two mounting bolts (Item 1) [Figure 20-62-


8] from the hydraulic pump.

Installation: Tighten the mounting bolts to 55-60 ft.-lbs.


(75-85 Nm) torque.

T190 Bobcat Loader


20-62-5 Service Manual
Figure 20-62-10

P-64446

Replace the O-ring (Item 1) [Figure 20-62-10] in the


hydrostatic pump.

Reverse the removal procedure to install the hydraulic


pump.

T190 Bobcat Loader


20-62-6 Service Manual
HYDRAULIC PUMP (SJC) (CONT'D)

Identification

15
14

7 5
12
8
5 6
4
12 3

9
8
7

11

5
6
10
9

7
3 4 5 6
1 1. Shaft Seal
2 2. Pump Flange Section
3. Pre-Load Seal
4. Load Seal
5. O-ring
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
10. Auxiliary Pump Section
11. Spline Shaft
12. Pump Center Section
13. Charge Pump Section
14. Pump End Section
15. Bolt (8)

B-21259A

T190 Bobcat Loader


20-62-7 Service Manual
HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-62-12

Disassembly And Assembly 1

Figure 20-62-11

P-26352
P-64507
1

1 P-64509

1
Remove the pump end section (Item 1) [Figure 20-62-
P-64508 12].

Mark the pump sections for correct assembly [Figure 20-


62-11].

Remove the eight pump housing bolts (Item 1) [Figure


20-62-11].

Installation: Tighten the bolts (Item 2) [Figure 20-62-11]


to 54 ft.-lbs. (73,2 Nm) torque.

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

T190 Bobcat Loader


20-62-8 Service Manual
HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-62-15

Disassembly And Assembly (Cont'd)

Figure 20-62-13 1

P-64511

2
Figure 20-62-16
P-64509

1
Figure 20-62-14

3
4

1
P-64512

2 Remove the charge pump section (Item 1) [Figure 20-


P-64510 62-15] & [Figure 20-62-16] from the pump center
section.

Remove the wear plate (Item 1) and section seal (Item 2) NOTE: Inspect the pump section (Item 1) [Figure 20-
[Figure 20-62-13] & [Figure 20-62-14] from the pump 62-16]. If excessive wear or damage is visible,
end section. the pump must be replaced.

NOTE: Position wear plate (Item 1) [Figure 20-62-14]


inlets and traps as shown with bronze side
toward gears.

NOTE: Inspect the pump end section (Item 3) [Figure


20-62-14] and bushings (Item 4) [Figure 20-62-
14]. If excessive wear or damage is visible, the
pump must be replaced.

T190 Bobcat Loader


20-62-9 Service Manual
HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-62-19

Disassembly And Assembly (Cont'd)

Figure 20-62-17

P-64515

Figure 20-62-20
P-64513

Figure 20-62-18

P-64516

Remove the idler gear (Item 1) [Figure 20-62-19] &


P-64514 [Figure 20-62-20] from the pump center section.

NOTE: Inspect the idler gear (Item 1) [Figure 20-62-


Remove the drive gear (Item 1) [Figure 20-62-17] & 20]. If excessive wear or damage is visible, the
[Figure 20-62-18]. pump must be replaced.

NOTE: Inspect the drive gear (Item 1) [Figure 20-62-


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

T190 Bobcat Loader


20-62-10 Service Manual
HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-62-23

Disassembly And Assembly (Cont'd)

Figure 20-62-21
1

P-64519

1
2 Figure 20-62-24
P-64517

2
Figure 20-62-22

2 1
P-64520

Remove the load seal (Item 1) [Figure 20-62-23] &


P-64518 [Figure 20-62-24]. Inspect for damage and replace as
needed.

Remove the wear plate (Item 1) and O-ring (Item 2) Remove the pre-load seal (Item 2) [Figure 20-62-24].
[Figure 20-62-21] & [Figure 20-62-22] from the pump
center section. Inspect for damage and replace as
needed.

NOTE: Position wear plate (Item 1) [Figure 20-62-22]


inlets and traps as shown with bronze side
toward gears.

T190 Bobcat Loader


20-62-11 Service Manual
HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-62-27

Disassembly And Assembly (Cont'd)

Figure 20-62-25
2

1
1
P-64526

Figure 20-62-28
P-64521
3

Inspect the pre-load seal (Item 1) [Figure 20-62-25] for


damage and replace as needed. 4
NOTE: Inspect the pump center section (Item 2) and
bushings (Item 3) [Figure 20-62-25]. If
excessive wear or damage is visible, the
pump must be replaced. 1

Figure 20-62-26

2
1
P-64527

Remove the wear plate (Item 1) and O-ring (Item 2)


[Figure 20-62-27] & [Figure 20-62-28] from the pump
center section. Inspect for damage and replace as
needed.

NOTE: Position wear plate (Item 1) [Figure 20-62-28]


inlets and traps as shown with bronze side
toward gears.

P-64525 NOTE: Inspect the pump center section (Item 3) and


bushings (Item 4) [Figure 20-62-28]. If
excessive wear or damage is visible, the
Remove the pump center section (Item 1) [Figure 20-62- pump must be replaced.
26].

T190 Bobcat Loader


20-62-12 Service Manual
HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-62-31

Disassembly And Assembly (Cont'd)

Figure 20-62-29
1

P-64530

1
Remove the drive gear (Item 1) [Figure 20-62-31] from
P-64528 the pump flange section.

Figure 20-62-32
Figure 20-62-30

P-64531
P-64529

NOTE: Inspect the drive gear (Item 1) [Figure 20-62-


Remove the auxiliary pump section (Item 1) [Figure 20- 32]. If excessive wear or damage is visible, the
62-29] & [Figure 20-62-30] from the pump flange pump must be replaced.
section.

NOTE: Inspect the pump section (Item 1) [Figure 20-


62-30]. If excessive wear or damage is visible,
the pump must be replaced.

T190 Bobcat Loader


20-62-13 Service Manual
HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-62-35

Disassembly And Assembly (Cont'd)

Figure 20-62-33

2
P-64535

Figure 20-62-36
P-64532

Remove the spline shaft (Item 1) [Figure 20-62-33] from


the end of the drive gear.

Remove the idler gear (Item 2) [Figure 20-62-33].

Figure 20-62-34

2
P-64536

Remove the wear plate (Item 1) and O-ring (Item 2)


1 [Figure 20-62-35] & [Figure 20-62-36] from the pump
flange section. Inspect for damage and replace as
needed.

NOTE: Position wear plate (Item 1) [Figure 20-62-36]


P-64534 inlets and traps as shown with bronze side
toward gears.

NOTE: Inspect the idler gear (Item 1) [Figure 20-62-


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

T190 Bobcat Loader


20-62-14 Service Manual
HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-62-39

Disassembly And Assembly (Cont'd)

Figure 20-62-37

3
2

1
P-64540

Inspect the pre-load seal (Item 1) [Figure 20-62-39] for


P-64537 damage and replace as needed.

NOTE: Inspect the pump flange section (Item 2) and


Figure 20-62-38 bushings (Item 3) [Figure 20-62-39]. If
excessive wear or damage is visible, the
pump must be replaced.

Figure 20-62-40

1
2
2
1 P-30188A

P-64538

Remove the load seal (Item 1) [Figure 20-62-37] &


[Figure 20-62-38]. Inspect for damage and replace as
P-64541
needed.

Remove the pre-load seal (Item 2) [Figure 20-62-38]. Remove the shaft seal (Item 1) [Figure 20-62-40] from
the pump flange section.

Installation: The shaft seal flush surface (Item 2)


[Figure 20-62-40] must be facing out away from the
pump.

T190 Bobcat Loader


20-62-15 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) Figure 20-63-2

Test The Output Of The Hydraulic Auxiliary Pump

WARNING
2 1
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

Figure 20-63-1 P-48256

Connect the INLET hose (Item 1) [Figure 20-63-2] from


the tester, to the OUTLET hose (Item 1) [Figure 20-63-1]
coming from the gear pump. Connect the OUTLET hose
1 (Item 2) [Figure 20-63-2] from the tester, to the INLET
tubeline (Item 2) [Figure 20-63-1] leading to the
hydraulic control valve.

IMPORTANT
P-64570 The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
The tools listed will be needed to do the following
procedure:

MEL1563 - Remote Start Tool


MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit

Lift and block the loader. (See Procedure on Page 10-10-


1.)

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

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Open the rear door of the loader.

Connect the remote start tool. (See Procedure on Page


10-60-1.)

Disconnect the OUTLET hose (Item 1) [Figure 20-63-1].

T190 Bobcat Loader


20-63-1 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Test The Output Of The Hydraulic Charge Pump

Test The Output Of The Hydraulic Auxiliary Pump


(Cont'd)

Figure 20-63-3
WARNING
EXAMPLE: TESTER Put jackstands under the front axles and rear corners
CONNECTION of the frame before running the engine for service.
Reservoir
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

Figure 20-63-4
Hydraulic Pump
Out In
Hydraulic Control
Valve
1 1
B-16277

Sample tester connection shown [Figure 20-63-3].

Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
2
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
P-64315
RPM*.

Warm the fluid to 140°F. (60°C.) by turning the restrictor The tools listed will be needed to do the following
control (Item 1) [Figure 20-63-3] on the tester to about procedure:
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free MEL1563 - Remote Start Tool
flow (GPM) at full RPM. MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit
Push the maximum/variable flow switch (on the remote
start tool) to engage the front auxiliary hydraulics. The Lift and block the loader. (See Procedure on Page 10-10-
light will come ON. Push the button (on the right control 1.)
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI) Raise the lift arms and install an approved lift arm support
and flow (GPM). The high pressure flow must be at least device. (See Installing Lift Arm Support Device on Page
80% of free flow. 10-20-1.)

%= HIGH PRESSURE FLOW (GPM) X100 Raise the operator cab. (See Raising The Operator Cab
FREE FLOW (GPM) on Page 10-30-1.)

Open the rear door of the loader.


A low percentage may indicate a failed pump.
Connect the remote start tool. (See Procedure on Page
(See LOADER SPECIFICATIONS on Page SPEC-10-1),
10-60-1.)
for system relief pressure and full RPM.
Disconnect the charge pump OUTLET hose (Item 1)
from the INLET fitting (Item 2) [Figure 20-63-4] at the
charge filter housing.

T190 Bobcat Loader


20-63-2 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Turn the restrictor down to 2000 PSI. DO NOT EXCEED
2000 PSI. The high pressure flow must be at least 80% of
Test The Output Of The Hydraulic Charge Pump free flow.
(Cont’d)
%= HIGH PRESSURE FLOW (GPM) X10
Figure 20-63-5
FREE FLOW (GPM) 0

A low percentage may indicate a failed pump.

*Refer to Hydraulic Schematics for pump flow and full


RPM.
2 1

P-48256

Connect the INLET hose (Item 1) [Figure 20-63-5] from


the tester, to the charge pump OUTLET hose (Item 1)
[Figure 20-63-4] coming from the gear pump. Connect
the OUTLET hose (Item 2) [Figure 20-63-5] from the
tester, to the INLET fitting (Item 2) [Figure 20-63-4] at
the charge filter housing.

IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.

Warm the fluid to 140°F. (60°C.) by turning the restrictor


control (Item 1) [Figure 20-63-3] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed 2000 PSI.

Open the restrictor control and record the free flow


(GPM) at full RPM.

T190 Bobcat Loader


20-63-3 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-6

Test The Output Of The Hydraulic Pump (High Flow)

WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286

P-48463

WARNING Install a jumper hose (Item 1) [Figure 20-63-6] onto the


front auxiliary quick couplers.
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
Raise the lift arms and install an approved lift arm support
support device. Failure to use an approved lift arm
device. (See Installing Lift Arm Support Device on Page
support device can allow the lift arms or attachment
10-20-1.)
to fall and cause injury or death.
W-2059-0598

IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

The tools listed will be needed to do the following


procedure:

MEL1563 - Remote Start Tool


MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit

Lift and block the loader. (See Procedure on Page 10-10-


1.)

Raise the operator cab. (See Raising The Operator Cab


on Page 10-30-1.)

Open the rear door of the loader.

Connect the remote start tool. (See Procedure on Page


10-60-1.)

T190 Bobcat Loader


20-63-4 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-9

Test The Output Of The Hydraulic Pump (High Flow) EXAMPLE: TESTER
(Cont'd) CONNECTION
Reservoir

Figure 20-63-7

Hydraulic Pump
Out In
High Flow Valve

1
1 B-16277

Sample tester connection shown [Figure 20-63-9].


2
P-48235 Start the engine and run at low idle RPM. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
Disconnect the high flow pump OUTLET hose (Item 1) coupler. Make sure the tester is connected correctly. If no
from the high flow valve INLET fitting (Item 2) [Figure 20- flow is indicated on the tester, the hoses are connected
63-7]. wrong. With the hoses connected correctly, increase the
engine speed to full RPM*.
Figure 20-63-8
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control (Item 1) [Figure 20-63-9] on the tester to about
1000 PSI (6895 kPa).

NOTE: DO NOT EXCEED 3300 PSI.

2 1 Open the restrictor control and record the free flow


(GPM) at full RPM. Turn the restrictor control on the
tester to 3300 PSI and the flow should go to zero GPM.

If pressure readings are not obtained go to the High Flow


Valve, relief valve adjustment procedure. (See High Flow
Relief Valve Adjustment Procedure on Page 20-100-3.)

P-48256 Record the highest pressure (PSI) and flow (GPM). The
high pressure flow must be at least 80% of free flow.
Connect the INLET hose (Item 1) [Figure 20-63-8] from
the tester, to the high flow pump OUTLET hose (Item 1) %= HIGH PRESSURE FLOW (GPM) X100
[Figure 20-63-7]. Connect the OUTLET hose (Item 2) FREE FLOW (GPM)
[Figure 20-63-8] from the tester, to the high flow valve
INLET fitting (Item 2) [Figure 20-63-7] on the High Flow A low percentage may indicate a failed pump.
valve.
*Refer to Hydraulic Schematics Legend for system relief
Lower the cab. pressure and full RPM.

T190 Bobcat Loader


20-63-5 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-11

Removal And Installation

2
Raise the lift arms and install an approved lift arm support
device. (See Installing Lift Arm Support Device on Page
P-64546
10-20-1.)

Lift and block the rear of the loader. (See Procedure on Disconnect and cap the outlet hoses (Item 1) [Figure 20-
Page 10-10-1.) 63-10] and [Figure 20-63-11] from the back of the
hydraulic pump.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) Remove the Power Bob-Tach block (Item 2) [Figure 20-
63-11] if equipped. (See Removal And Installation on
Drain the hydraulic fluid from the reservoir. (See Page 20-120-1.)
Replacing Hydraulic Fluid on Page 10-120-2.)
Figure 20-63-12
Open the rear door of the loader.

WARNING
Never work on a machine with the lift arms up unless 1
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death. 1
W-2059-0598

Figure 20-63-10
P-64544

Disconnect and cap the inlet hoses (Item 1) [Figure 20-


63-12] from the front of the hydraulic pump.

P-64545

T190 Bobcat Loader


20-63-6 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-14

Removal And Installation (Cont’d)

Figure 20-63-13

3
1

1
2

P-64343

Remove the bracket mounting bolt (Item 1) from the


P-64549 pump mounting bracket (Item 2) [Figure 20-63-14].

Note: The mounting bolt is a special purpose bolt.


Remove the two mounting bolts (Item 1) [Figure 20-63- Only replace with original Bobcat Parts.
13] from the hydraulic pump.
Installation: Apply a medium strength threadlocker to
Installation: Tighten the mounting bolts to 55-60 ft.-lbs. mounting bolt and tighten to 90-100 ft.-lbs. (122-136 Nm)
(75-85 Nm) torque. torque.

Remove the mounting bracket (Item 2) [Figure 20-63-


14].

Remove the hydraulic pump (Item 3) [Figure 20-63-14]


from the hydrostatic pump.

Figure 20-62-15

P-64446

Replace the O-ring (Item 1) [Figure 20-62-15] in the


hydrostatic pump.

Reverse the removal procedure to install the hydraulic


pump.

T190 Bobcat Loader


20-63-7 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D)

Identification

17
16

8 4
12 15 2
7

14 3 4 5

7
8 13 6 5

9
6
7

12
7
8
7
9 6
5
3 4

6 5 11

6 9
5 10
1 3 4
1. Shaft Seal
2. Pump Flange Section
2
3. Pre-Load Seal
4. Load Seal
5. O-Ring
6. Valve Plate
7. Pin
8. Drive Gear
9. Idler Gear
10. Auxiliary Pump Section
11. Auxiliary Center Section
12. Splined Shaft
13. Charge Pump Section
14. Charge Center Section
15. High Flow Pump Section
16. High Flow End Section
17. Bolt

B-18248

T190 Bobcat Loader


20-63-8 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-17

Disassembly And Assembly 1

Figure 20-63-16

1
P-64553

P-64554
1
1
Remove the high flow end section (Item 1) [Figure 20-
P-64552 63-17].

Mark the pump sections for correct assembly [Figure 20-


63-16].

Remove the eight pump housing bolts (Item 1) [Figure


20-63-16].

Installation: Tighten the bolts (Item 2) [Figure 20-63-16]


to 54 ft.-lbs. (73,2 Nm) torque.

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

T190 Bobcat Loader


20-63-9 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-20

Disassembly And Assembly (Cont'd)

Figure 20-63-18 1

P-64556

2
Figure 20-63-21
P-64554

1
Figure 20-63-19

3
4

1
P-64557

2
Remove the high flow pump section (Item 1) [Figure 20-
P-64555 63-20] & [Figure 20-63-21] from the charge center
section.

Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the high flow pump section (Item 1)
[Figure 20-63-18] & [Figure 20-63-19] from the high flow [Figure 20-63-21]. If excessive wear or
end section. damage is visible, the pump must be
replaced.
NOTE: Position wear plate (Item 1) [Figure 20-63-19]
inlets and traps as shown with bronze side
toward gears.

NOTE: Inspect the high flow end section (Item 3) and


bushings (Item 4) [Figure 20-63-19]. If
excessive wear or damage is visible, the
pump must be replaced.

T190 Bobcat Loader


20-63-10 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-24

Disassembly And Assembly (Cont'd)

Figure 20-63-22

P-64560

Figure 20-63-25
P-64558

Figure 20-63-23

P-64561

Remove the idler gear (Item 1) [Figure 20-63-24] &


P-64559 [Figure 20-63-25] from the charge center section.

NOTE: Inspect the idler gear (Item 1) [Figure 20-63-


Remove the drive gear (Item 1) [Figure 20-63-22] & 25]. If excessive wear or damage is visible, the
[Figure 20-63-23]. pump must be replaced.

NOTE: Inspect the drive gear (Item 1) [Figure 20-63-


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

T190 Bobcat Loader


20-63-11 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-28

Disassembly And Assembly (Cont'd)

Figure 20-63-26

P-64564

2
Figure 20-63-29
P-64562

2
Figure 20-63-27

2
1
P-64565

Remove the load seal (Item 1) [Figure 20-63-28] &


P-64563 [Figure 20-63-29]. Inspect for damage and replace as
needed.

Remove the wear plate (Item 1) and O-ring (Item 2) Remove the pre-load seal (Item 2) [Figure 20-63-29].
[Figure 20-63-26] & [Figure 20-63-27] from the charge
center section. Inspect for damage and replace as
needed.

NOTE: Position wear plate (Item 1) [Figure 20-63-27]


inlets and traps as shown with bronze side
toward gears.

T190 Bobcat Loader


20-63-12 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-32

Disassembly And Assembly (Cont'd)

Figure 20-63-30 2

3
1

1
P-64569

Figure 20-63-33
P-64567
3

Inspect the pre-load seal (Item 1) [Figure 20-63-30] for


damage and replace as needed. 4
NOTE: Inspect the charge center section (Item 2) and
bushings (Item 3) [Figure 20-63-30]. If
excessive wear or damage is visible, the
pump must be replaced.
1
Figure 20-63-31

2
1 P-64571

Remove the wear plate (Item 1) and O-ring (Item 2)


[Figure 20-63-32] & [Figure 20-63-33] from the charge
center section. Inspect for damage and replace as
needed.

NOTE: Position wear plate (Item 1) [Figure 20-63-33]


inlets and traps as shown with bronze side
toward gears.

P-64568 NOTE: Inspect the charge center section (Item 3) and


bushings (Item 4) [Figure 20-63-33]. If
excessive wear or damage is visible, the
Remove the charge center section (Item 1) [Figure 20- pump must be replaced.
63-31].

T190 Bobcat Loader


20-63-13 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-36

Disassembly And Assembly (Cont'd)

Figure 20-63-34

1 1

P-64574

Remove the drive gear (Item 1) [Figure 20-63-36] from


P-64572 the auxiliary center section.

Figure 20-63-37
Figure 20-63-35

P-64575
P-64573

NOTE: Inspect the drive gear (Item 1) [Figure 20-63-


Remove the charge pump section (Item 1) [Figure 20- 37]. If excessive wear or damage is visible, the
63-34] & [Figure 20-63-35] from the auxiliary pump pump must be replaced.
center section.

NOTE: Inspect the charge pump section (Item 1)


[Figure 20-63-35]. If excessive wear or
damage is visible, the pump must be
replaced.

T190 Bobcat Loader


20-63-14 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-40

Disassembly And Assembly (Cont'd)

Figure 20-63-38

1 2
2
P-64578

Figure 20-63-41
P-64576

Remove the spline shaft (Item 1) [Figure 20-63-38] from


the end of the drive gear. Inspect for damage and replace
as needed.

Remove the idler gear (Item 2) [Figure 20-63-38]. 1

Figure 20-63-39 2

P-64579

1
Remove the wear plate (Item 1) and O-ring (Item 2)
[Figure 20-63-40] & [Figure 20-63-41] from the auxiliary
center section. Inspect for damage and replace as
needed.

NOTE: Position wear plate (Item 1) [Figure 20-63-41]


inlets and traps as shown with bronze side
P-64577 toward gears.

NOTE: Inspect the idler gear (Item 1) [Figure 20-63-


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

T190 Bobcat Loader


20-63-15 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-44

Disassembly And Assembly (Cont'd) 2

Figure 20-63-42

1
1

P-64521

Inspect the pre-load seal (Item 1) [Figure 20-63-44] for


P-64519 damage and replace as needed.

NOTE: Inspect the auxiliary center section (Item 2)


Figure 20-63-43 and bushings (Item 3) [Figure 20-63-44]. If
excessive wear or damage is visible, the
pump must be replaced.
2
Figure 20-63-45

1
P-64520

Remove the load seal (Item 1) [Figure 20-63-42] &


[Figure 20-63-43]. Inspect for damage and replace as
P-64525
needed.

Remove the pre-load seal (Item 2) [Figure 20-63-43]. Remove the auxiliary center section (Item 1) [Figure 20-
63-45].

T190 Bobcat Loader


20-63-16 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-48

Disassembly And Assembly (Cont'd)

Figure 20-63-46

P-64528
1

Figure 20-63-49
P-64526

Figure 20-63-47

4
1

1
P-64529

2 Remove the auxiliary pump section (Item 1) [Figure 20-


P-64527 63-48] & [Figure 20-63-49] from the pump flange
section.

Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the auxiliary pump section (Item 1)
[Figure 20-63-46] & [Figure 20-63-47] from the auxiliary [Figure 20-63-49]. If excessive wear or
center section. Inspect for damage and replace as damage is visible, the pump must be
needed. replaced.

NOTE: Position wear plate (Item 1) [Figure 20-63-47]


inlets and traps as shown with bronze side
toward gears.

NOTE: Inspect the auxiliary center section (Item 3)


and bushings (Item 4) [Figure 20-63-47]. If
excessive wear or damage is visible, the
pump must be replaced.

T190 Bobcat Loader


20-63-17 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-52

Disassembly And Assembly (Cont'd)

Figure 20-63-50

1
1

P-64532

Remove the spline shaft (Item 1) [Figure 20-63-52] from


P-64530 the end of the drive gear.

Remove the idler gear (Item 2) [Figure 20-63-52].


Remove the drive gear (Item 1) [Figure 20-63-50] from
the pump flange section. Figure 20-63-53

Figure 20-63-51

1
1

P-64534

P-64531
Remove the idler gear (Item 1) [Figure 20-63-53] from
the pump flange section.
NOTE: Inspect the drive gear (Item 1) [Figure 20-63-
51]. If excessive wear or damage is visible, the NOTE: Inspect the idler gear (Item 1) [Figure 20-63-
pump must be replaced. 53]. If excessive wear or damage is visible, the
pump must be replaced.

T190 Bobcat Loader


20-63-18 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-56

Disassembly And Assembly (Cont'd)

Figure 20-63-54

P-64537

Figure 20-63-57
P-64535

Figure 20-63-55

1 P-64538

Remove the load seal (Item 1) [Figure 20-63-56] &


2
P-64536 [Figure 20-63-57]. Inspect for damage and replace as
needed.

Remove the wear plate (Item 1) and section seal (Item 2) Remove the pre-load seal (Item 2) [Figure 20-63-57].
[Figure 20-63-54] & [Figure 20-63-55] from the pump
flange section. Inspect for damage and replace as
needed.

NOTE: Position wear plate (Item 1) [Figure 20-63-55]


inlets and traps as shown with bronze side
toward gears.

T190 Bobcat Loader


20-63-19 Service Manual
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-59

Disassembly And Assembly (Cont'd)

Figure 20-63-58
1

2
P-30188A

3
2

P-64541

Remove the shaft seal (Item 1) [Figure 20-63-59] from


1
P-64540 the pump flange section.

Installation: The shaft seal flush surface (Item 2)


Inspect the pre-load seal (Item 1) [Figure 20-63-58] for [Figure 20-63-59] must be facing out away from the
damage and replace as needed. pump.

NOTE: Inspect the pump flange section (Item 2) and


bushings (Item 3) [Figure 20-63-58]. If
excessive wear or damage is visible, the
pump must be replaced.

T190 Bobcat Loader


20-63-20 Service Manual
HYDRAULIC/HYDROSTATIC FILTER HOUSING Figure 20-70-2

Removal And Installation

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,


2
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
3

P-48260
Implement Filter Housing

Figure 20-70-1 Disconnect the wires from the charge pressure sender
(Item 1) [Figure 20-70-2] from the filter housing.

Disconnect the temperature sender connector (Item 2)


[Figure 20-70-2] from the filter housing.

Disconnect the wire connector (Item 3) [Figure 20-70-2]


from the differential pressure switch on the filter housing.
1
Figure 20-70-3

P-48259
1

Stop the engine and open the rear door.

Drain the hydraulic fluid. (See Replacing Hydraulic Fluid


on Page 10-120-2.)

Remove the two mounting bolts (Item 1) and remove the


hydraulic filter drip pan (Item 2) [Figure 20-70-1]. P-48257

Disconnect the tubeline (Item 3) [Figure 20-70-1] from


the filter housing. Using MEL 1558 tool disconnect the oil cooler tubeline
(Item 1) [Figure 20-70-3] from the filter housing.

T190 Bobcat Loader


20-70-1 Service Manual
HYDRAULIC/HYDROSTATIC FILTER HOUSING Charge Filter Housing
(CONT’D)
Stop the engine and open the rear door.
Removal And Installation (Cont’d)
Drain the hydraulic fluid. (See Replacing Hydraulic Fluid
Figure 20-70-4 on Page 10-120-2.)

Figure 20-70-5
1

P-48258
1

P-64315
Remove the two