Service Manual TJ430

330 / 430 LOG LOADER
S/N – CB1066 – CE1313

S/N – 961314 – 961314
TECHNICAL MANUAL
330 / 430 LOG LOADER
TMF278359
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.
WARNING
The engine exhaust from this product contains

chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
Worldwide Construction and Forestry Division

English
Service Manual
Model 330 and 430 Loaders

Timberjack Inc.
P.O. Box 160
925 Devonshire Avenue
Woodstock, Ontario, Canada
N4S 7X1
Telephone: 519-537-6271
Service Dept. Fax: 519-537-2664
Parts Dept. Fax:
10/96.
Table of Contents
Section Description
1 Introduction
2 Safety Rules
3 Theory of Operation
4 Specifications
5 Test Procedures
6 Hydraulic System
7 Electrical System
8 Troubleshooting
9 Maintenance and Repair
10 OEM Documentation
M43000TC i
Table of Contents
Section 1 - Introduction
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Non-approved Field Product Changes . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 Warranty Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4 Items Not Covered by Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Section 2 - Safety Rules

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Safety Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Understanding Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5 Operating Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6 Servicing Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.7 Transporting on Public Roads . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15
2.8 Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15
2.9 What to Do if the Machine Catches Fire . . . . . . . . . . . . . . . . . . . . . 2 - 16
Section 3 - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . Not Available
Section 4 - Specifications
4.1 Machine Dimensions - 330 Log Loader . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Machine Dimensions - 430 Log Loader . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Equipment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Fluid and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.1 Fluid and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.2 Engine Oil Viscosity - Cummins . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4.3 Engine Oil Viscosity - John Deere . . . . . . . . . . . . . . . . . . . . . 4-9
4.4.4 Gear Oil Viscosity - Swing Drive Gearbox . . . . . . . . . . . . . . . . 4 - 10
4.4.5 Hydraulic Lubrication and Fluid Recommendation . . . . . . . . . . . 4 - 11
4.4.6 Recommended Hydraulic Fluid Brands . . . . . . . . . . . . . . . . . 4 - 13
4.5 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
4.5.1 Steel Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
4.5.2 Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18
ii M43000TC
Table of Contents
Section 5 - Test Procedures and Adjustments
5.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.1.1 Hydraulic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.1.2 Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2 Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2.2 Jib Valve - Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.2.3 Jib Valve - Swing Section . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.2.4 Pilot Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 12
5.2.5 Delimber Valve Pressure Relief (Swivel Machines) . . . . . . . . . . . . 5 - 13
5.2.6 SPI Bar Saw Valve Main Relief . . . . . . . . . . . . . . . . . . . . . . 5 - 14
5.2.7 SPI Pilot Priority Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15
5.2.8 SPI Pilot Priority Relief . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 16
5.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Available
Section 6 - Hydraulic Systems

6.1 Hydraulic System Schematic - SPI . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
6.2 Hydraulic System Schematic - Swivel . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
Section 7 - Electrical Systems

7.1 Electrical Schematic - SPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2
7.2 Electrical Schematic - Swivel, Joysticks . . . . . . . . . . . . . . . . . . . . . . 7 - 4
7.3 Electrical Schematic - Swivel, Lever Controls . . . . . . . . . . . . . . . . . . . 7 - 6
Section 8 - Troubleshooting
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Section 9 - Maintenance and Repair

Group 10 - Power Unit and Auxiliary Systems . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 1
10.1 Engine Rubber Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 2
10.1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 3
10.1.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 3
10.1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 3
M43000TC iii
Table of Contents
10.2 Engine Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 4
10.2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 5
10.2.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 5
10.2.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 5
10.3 Pump Adapter and Drive Plate . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 6
10.3.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 6
10.3.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 6
10.4 Engine Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 7
10.4.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 7
10.4.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 9
10.5 Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 10
10.5.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 10
10.5.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 11
10.6 Swing Gearbox Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 12
10.6.1 Swing Gearbox Components . . . . . . . . . . . . . . . . . . . . 9 - 10 - 12
10.6.2 Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 13
10.6.3 First Stage Planetary Carrier Disassembly . . . . . . . . . . . . . 9 - 10 - 19
10.6.4 First Stage Planetary Carrier Assembly . . . . . . . . . . . . . . 9 - 10 - 20
10.6.5 Second Stage Planetary Carrier Disassembly . . . . . . . . . . . 9 - 10 - 21
10.6.6 Second Stage Planetary Carrier Assembly . . . . . . . . . . . . 9 - 10 - 22
10.6.7 Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 23
10.7 Swing Gearbox Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 29
10.8 Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 32
10.8.2 Removal/Installation - Cummins Engine . . . . . . . . . . . . . . 9 - 10 - 33
10.8.3 Removal/Installation - John Deere Engine . . . . . . . . . . . . . 9 - 10 - 34
10.9 Hydraulic Fluid Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 35
10.9.2 Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 35
10.10 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 36
10.10.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 38
10.10.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 38
10.11 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 39
10.12 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 41
iv M43000TC
Table of Contents
Group 20 - Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 1
20.1 Triple Section Main Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 3
20.1.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 3
20.1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 5
20.2 Triple Section Main Pump Repair . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 7
20.2.2 Triple Section Main Pump Components . . . . . . . . . . . . . . . 9 - 20 - 8
20.2.3 Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 10
20.2.4 Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 14
20.3 Dual Section SPI Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 23
20.3.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 23
20.3.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 26
20.4 Dual Section SPI Pump Repair . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 28
20.4.2 Dual Section SPI Pump Components . . . . . . . . . . . . . . . 9 - 20 - 28
20.4.3 Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 30
20.4.4 Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 34
20.4.5 Priority Valve Disassembly . . . . . . . . . . . . . . . . . . . . 9 - 20 - 41
20.4.6 Priority Valve Assembly . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 42
20.5 Inspection and Parts Replacement . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 43
20.6 Recommended Start-up Procedure . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 46
20.7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 47
20.8 Pilot Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 49
20.8.2 Removal/Installation - Engine Mounted Pump (Cummins) . . . . 9 - 20 - 49
20.8.3 Removal/Installation - Belt Driven Pump (John Deere) . . . . . . 9 - 20 - 51
20.9 Pilot Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 54
20.10 Swing Gear Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 55
20.10.1 General Information . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 55
20.10.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 55
20.10.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 56
20.11 Swing Gear Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 57
20.11.2 Swing Gear Motor Components . . . . . . . . . . . . . . . . . 9 - 20 - 58
20.11.3 Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 59
20.11.4 Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 61
M43000TC v
Table of Contents
20.12 SPI Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 65
20.12.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 66
20.12.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 67
20.13 SPI Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 69
20.13.2 SPI Motor Components . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 70
20.13.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 71
20.13.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 73
20.14 Inspection and Parts Replacement . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 77
20.15 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 78
20.16 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 79
20.16.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 66
20.16.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 67
20.17 Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 81
20.17.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 81
20.17.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 84
20.18 Control Valve Section Repair . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 85
20.18.1 Lever Operated Spool Section . . . . . . . . . . . . . . . . . . 9 - 20 - 85
20.18.2 Pilot Operated Spool Section . . . . . . . . . . . . . . . . . . . 9 - 20 - 87
20.18.3 Solenoid Operated Spool Section . . . . . . . . . . . . . . . . . 9 - 20 - 90
20.18.4 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 93
20.19 Relief Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 94
20.20 Pilot Solenoid Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 95
20.21 On-Machine Control Valve Repair . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 96
20.22 Joystick Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 97
20.23 Joystick Control Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 98
20.23.1 Off-Machine Joystick Repair . . . . . . . . . . . . . . . . . . . 9 - 20 - 98
20.23.2 On-Machine Joystick Repair . . . . . . . . . . . . . . . . . . . 9 - 20 - 99
20.24 Detent Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 101
20.24.2 Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 101
20.25 Detent Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 102
20.26 Main Hydraulic Filter Assembly (SPI) . . . . . . . . . . . . . . . . . . 9 - 20 - 103
vi M43000TC
Table of Contents
20.27 Pilot In-line Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 104
20.28 Main Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 105
20.28.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 105
20.28.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 106
20.29 Hydraulic Tank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 107
20.30 Lower Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 109
20.30.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 109
20.30.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 110
20.31 Lower Hydraulic Tank Repair . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 111
20.32 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 112
20.32.2 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 113
20.33 Hydraulic Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 115
20.33.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 115
20.33.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 116
20.34 Hydraulic Swivel Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 117
20.34.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 117
20.35.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 - 118
M43000TC vii
viii M43000TC
.
Section 1
10/1996 Introduction
1. Introduction
1.1 Foreword 1-2

1.2 Non-approved Field Product Changes 1-4
1.3 Warranty Certificate 1-5
1.4 Items Not Covered By Warranty 1-7
M4301001 1-1
Section 1
Introduction 10/1996
1.1 Foreword
This service manual provides detailed instructions for troubleshooting, maintenance and repair which includes
removal/installation, inspection, and replacement. Also included are test procedures and specifications of the various
systems making up the Timberjack 330/430 Log Loader.
Use this manual as an on-the-job guide and quick reference. The information contained are kept as brief as possible
to enable the service technician to quickly grasp the needed informations.
Wherever references are made to the front, rear, left and right side of the machine. Consider the machine a two-part
unit where the platform and outriggers constitute the base, and the superstructure, including the booms, constitute
the turntable. On the base the front end is that end pointing toward the cab of the truck or neck of the trailer on which
the loader is mounted. The left and right sides of the base are determined from a position behind the truck or trailer
looking forward. On the turntable the booms are at the front and the left and right hand sides are determined from a
seated position in the operator’s seat facing the booms.
Where applicable, throughout the text, "Safety Alert" symbols have been used to indicate important safety
measures. Read carefully, understand, and follow these instructions to prevent hazardous situations that
could lead to risk of personal injury.
The information contained in this manual is current at the time of publication; however, continuing product
improvement may result in changes to the machine or its components which are not covered. Should information
regarding such changes or any further information be required, please contact your Timberjack Inc. service
representative.
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.
1-2 M4301001
Section 1
1.2 Non-approved Field Product Changes
Changes of any kind to the Timberjack Inc. product Timberjack Inc. disclaims responsibility for any situation
including the fitting of any unauthorized attachments that may arise as a result of unauthorized change to its
could affect the integrity of the product, its stability, or its product.
ability to perform as designed or intended.
If any person or organization modifies or contributes in

any way to unauthorized modification, the person or
organization will be deemed to have assumed the risk
involved with such modification and may be deemed
IT IS TIMBERJACK INC. POLICY THAT NO CHANGES negligent in creating a dangerous situation resulting
ARE TO BE MADE TO ITS PRODUCTS INCLUDING from such action.
DELETIONS OR ADDITIONS OTHER THAN A
TIMBERJACK APPROVED OPTION FITTED IN THE
FACTORY APPROVED MANNER.
Where changes are made without the official approval
as described above, and Timberjack Inc. becomes
involved in suit arising out of such change,
Timberjack Inc. will protect its interest by taking
whatever action is appropriate.
Options or changes are only officially approved in the

following form:
Failure to adhere to this policy NULLIFIES and VOIDS
both the product warranty policy and the certification on
a) Standard options for that product shown or listed on any safety items installed on the modified machine.
a current, printed specification sheet, price list, parts
manual, or product literature issued by
Timberjack Inc.
Non-approved product changes also nullify warranties
given to Timberjack Inc. by its component manufacturers.
b) Clearly specified options or product changes
approved in writing by the Timberjack Inc. Vice
President - Engineering.
Timberjack Inc.
NO OTHER PERSON IS AUTHORIZED TO GIVE Woodstock, Ontario, Canada
SUCH APPROVAL. April, 1996.
M4301001 1-3
Section 1
Introduction 10/1996
1.3 Warranty Certificate - Timberjack Loaders
Standard Warranty. Compensation under this warranty may be denied if

repairs or alterations to a Timberjack Inc. log loader
Timberjack Inc. warrants each new Timberjack Inc. log have been made by persons or firms not specifically
loader to be free of failure resulting from defective approved by Timberjack Inc. so as in Timberjack Inc.’s
material and workmanship under proper use and service opinion to adversely affect in any way the stability and
for a period of three hundred and sixty-five (365) days or reliability of such machine. The installation in such
two thousand (2000) hours, whichever first occurs, machine of any product or attachment not specifically
following date of delivery of the machine to the original approved by Timberjack Inc. may also result in denial of
retail customer (user) provided that the prescribed warranty.
pre-delivery, start-up and follow-up inspections have
been carried out and reported to Timberjack Inc. to
validate all aspects of this warranty. Liability or obligation on the part of Timberjack Inc. for
damages, whether general, special, or for negligence
and expressly including any incidental and
consequential damages, is hereby disclaimed.
Timberjack Inc.’s sole obligation under this warranty is Timberjack Inc.’s obligation to repair or replace shall be
limited to the repair or replacement without charge at the limit of its liability under this warranty and the sole
Timberjack Inc.’s factory, warehouse, or approved repair and exclusive right and remedy of the user.
shop, any part or parts which which Timberjack Inc.’s
inspection shall disclose to have been defective in
material or workmanship. Parts which show evidence of THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL
neglect, overload, abuse,accident, inadequate OTHER WARRANTIES, EXPRESS OR IMPLIED,
maintenance or unauthorized alteration are not covered. WRITTEN OR ORAL, INCLUDING WITHOUT
LIMITATION, ANY IMPLIED WARRANTIES OF
MERCHANTABILITY OR OF FITNESS FOR A
PARTICULAR PURPOSE.
Timberjack Inc. is not responsible for any costs
associated with delivery of the machine to an authorized
repair shop, nor any costs associated with delivery of The distributor agrees to extend only the above warranty
parts to make the repairs. to it’s customers. In the event the distributor extends to
it’s customer any additional warranty such as by
extending the scope or period of warranty or undertaking
a warranty of fitness for any particular purpose or any
This warranty, in its entirety, does not cover other obligation not encompassed in Timberjack Inc.’s
maintenance items in Timberjack Inc. log loaders, which warranty, then the distributor shall be solely responsible
includes, but is not limited to lubricating grease and oils, therefor and shall have no recourse against Timberjack
filters, hoses,belts, ignition parts or clutches. Inc. with respect thereto.
This warranty may not be changed, altered, or modified

Alternators, regulators, engines, starter motors, injection in any way except in writing by the
pumps, and allied equipment are warranted by the Vice President - Engineering of Timberjack Inc.
manufacturers of same to the user and are not
warranted by Timberjack Inc.. Warranty on all such
parts, components, or items are limited to the warranty, Timberjack Inc.
if any, offered by the original manufacturer of same. Woodstock, Ontario, Canada
October, 1996.
1-4 M4301001
Section 1
1.4 Items Not Covered By Warranty:

Items and service related functions that are not covered by warranty include, but are not limited to:
1. Issues resulting from misuse, negligence or accident.

2. Issues arising from the use of non approved parts.
3. Repairs or adjustment by other than Timberjack Inc. or its authorized dealers.

4. Engine Tune-up.
5. Issues resulting from the installation of unauthorized attachments or modifications.

6. Transportation of the machine to or from the repair location.
7. Dealer travel or mileage expense.

8. Injection pump and injector adjustments.
9. Air, oil and fuel filter elements.

10. Air conditioning filters, freon, receiver dryer.
11. Diagnosis time will not be considered warranty labor.

12. Tightening of nuts, bolts, screws, etc. or adjustments.
13. Natural wear or defects caused by natural wear.

14. Issues due to use of improper fuel, oil, grease, coolant, or other fluid or lubricant.
15. Freight expenses, daily allowances and overtime labor rates.

16. Damage occurring while in dealer inventory or in transit from the factory to dealer and from dealer to customer.
17. Indirect damages such as loss of earnings, etc.
18. Normal Maintenance services. Maintenance services that are not directly involved with defective parts are
considered normal service and should be excluded from a claim. These services include (but are not limited to):
Fuel system cleaning
Engine tune-up
Other adjustments (but not limited to) such as:

Tightening of hydraulic fittings
Adding or replacing of service fluid and filters
Replacement of air, hydraulic, transmission, engine fuel filters, oil, belts, and breathers.
Hydraulic pressure adjustments.
M4301001 1-5
.
Section 2
10/1996 Safety Rules
2. Safety Rules
2.1 General 3-2

2.2 Safety Symbol 3-2
2.3 Understanding Signal Words 3-2
2.4 General Safety Precautions 3-3
2.5 Operating Safety Precautions 3-6
2.6 Servicing Safety Precautions 3-9
2.7 Transporting on Public Roads 3 - 15
2.8 Fire Prevention 3 - 15
2.9 What to Do if the Machine Catches Fire 3 - 16
M4302001 2-1
Section 2
Safety Rules 10/1996
2.1 General
Should there be any information or instructions in this
manual that are not in compliance with local laws and
regulations in force in the country or region where this
equipment is operated, the local laws and regulations
must take precedence.
This machine should not be operated or maintained by

personnel other than those who have been thoroughly
trained.
As the operator/maintainer ensure that you become

familiar with all occupational safety regulations
pertaining to forest machinery as well as all safety
instructions pertaining to this equipment. Observe the
instructions provided in this manual and on all hazard
and information decals on the machine.
2.2 Safety Symbol

This safety-alert symbol is used throughout the manual
and on the machine to call your attention to areas in
which carelessness or failure to follow specific
procedures may result in personal injury.
2.3 Understanding Signal

Words
DANGER identifies the most serious hazards where
DANGER failure to follow listed procedures would result in a high
probability of death or serious injury.
WARNING denotes a hazard exists which can result in

WARNING serious injury or death if proper precautions are not
taken.
CAUTION is used in areas where failure to follow listed

CAUTION procedures may cause personal injury.
2-2 M4302001
Section 2
2.4 General Safety

Precautions
Timberjack Inc. policy is to produce products that are

safe and reliable. However, even when using well
designed equipment, there will always be an element of
risk in heavy-duty equipment operation.
To minimize risks and promote safety at all times, this

section of the operator’s manual details a number of
safety rules which should always be followed and
obeyed.
Study all the safety messages in this manual and on the

machine carefully.
You must be fully trained to operate this equipment.

Know the capabilities and the limitations of the
equipment. Learn the most efficient operating
techniques.
Do not let an untrained person operate the machine.
Use recommended protective clothing and safety

devices such as gloves, safety boots, safety hat,
goggles, and ear protection when necessary.
These safety rules highlight both general and specific

measures the operator should be familiar with and
adhere to. More specific measures are illustrated with
pictograms which may also be attached to the
machine in locations pertinent to their respective
message. Keep safety signs in good condition.
Repair or replace damaged signs.
WHEN IT COMES TO SAFETY, NOTHING WILL EVER

REPLACE A CAREFUL OPERATOR.
M4302001 2-3
Section 2
2.4 General Safety

Precautions
Wear a suitable hearing protective device such as

earmuffs or ear plugs to protect against noise.
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Use the handrails and steps provided when mounting

and dismounting the machine.
Face the machine when mounting and dismounting.
Maintain a three-point contact (one foot and two hands

or two feet and one hand) with the steps and handrails.
Do not climb on or off the machine in any other fashion.
Use a hand line to lift tools or supplies onto the machine.
Inspect the machine daily and when necessary, clean or

repair the handrails and steps.
Keep floors, steps, and running boards clean and free of

oil, ice, mud, and loose objects.
2-4 M4302001
Section 2
2.4 General Safety

Precautions
Keep a first aid kit in an easily accessible location on the

vehicle at all times.
Carry no passengers. The vehicle is provided and

approved with seating for the operator only.
The seat is equipped with seat belt. Use this belt at all
times when operating the machine.
Comply with instructions in this manual and also your

company’s regulations for the operation of this vehicle.
Operate the machine only when physically fit and not

under the influence of alcohol or drugs.
M4302001 2-5
Section 2
2.5 Operating Safety

Precautions
Before starting the engine, check, and ensure that all
doors, panels, safety screens, and access covers are
installed properly and secured.
Do not operate the machine if any exhaust system

covers, safety covers, safety screens, or other safety
devices are damaged, removed, or missing.
Check the fire extinguishing equipment. Ensure that the

fire extinguisher bottles are fully charged and the
equipment is in good working order.
Operate the machine only from a seated position in the

operator’s seat with the seat belt buckled up.
Never use a liquid starting aid to start an engine with a

pre-heat device.
Start the engine according to the instructions in this

manual.
2-6 M4302001
Section 2

Precautions
Prior to commencing work, check all equipment controls
and ensure that the machine responds correctly.
When operating the machine, keep the door closed to

prevent accidental entry of branches and debris into the
cab.
Always lower the booms and grapple into a securely

supported position before the operation is stopped.
When moving the machine, watch that enough

clearance is available on both sides and above the
boom. Extra clearance may be required particularly
where the ground is uneven.
Maintain a safe operating distance between the

equipment and other personnel. Never swing the boom,
attachment, or load over the heads of bystanders
USE ONLY PREARRANGED AND APPROVED

SIGNALING PRACTICES.
When the engine is running, allow no one in areas of the

machine where they may be crushed by moving
components.
M4302001 2-7
Section 2

Precautions
Operate, with caution, in areas where overhanging
telephone or electric power lines are present.
Serious injury or death by electrocution can result if the

machine or any of its attachments are not kept a safe
distance from high-voltage electric power lines.
Maintain a distance of 10 ft. (3 m) between the machine

or boom and any power line carrying up to 50,000 Volts
or less.
Power lines carrying more than 50,000 Volts require a

safety distance of 10 ft. (3 m) plus 1/2 inch (13 mm) for
each additional 1,000 Volts above the 50,000 Volt level.
If state/province, local or job site regulations require

even greater safety distances than stated above,adhere
strictly to these regulations for your own protection.
Never dismount from moving equipment. Observe

proper shutdown practices before dismounting.
Check for slippery steps and handholds and dismount

the machine carefully. Do not hang on to any controls
and never jump off the machine.
Stop the engine and relieve any pressure trapped in the

hydraulic system.
Turn the master disconnect switch off if the machine is

to be left unattended.
2-8 M4302001
Section 2
2.6 Servicing Safety

Precautions.
If the machine becomes disabled, attach a warning tag
to a joystick or control lever. If the machine should not
be started, remove the ignition key and, as applicable,
turn the master disconnect switch to off.
Before undertaking any maintenance or repair work,

obtain permission. DO NOT perform any maintenance
work without authorization.
Consult the manufacturer’s instruction manual and

follow recommended procedures.
Safety face shield, glasses, or goggles should always be

used as protection from pressurized fluid spray, flying
debris, and other airborne matter when working with
tools, power tools, welding equipment, and corrosive or
dangerous chemicals.
Wear protective clothing as required by the job. Use a

rubber apron and rubber gloves when working with
corrosives and wear heavy work gloves and safety
shoes when handling large heavy or sharp objects and
cables.
M4302001 2-9
Section 2

Precautions
WARNING
Keep clear of all rotating components. Wrapping,
entanglement or contact may result in serious
injury or death.
Keep clear of exposed fans and drive belts.
Never wear jewelry, watch, or necktie around any

machinery. Keep your hands, feet, head, and loose
clothing away from drive shafts and other power driven
parts.
WARNING
Never work on the machine with the engine running
unless instructed to by this manual for specific
service items.
Lower the implements into supported position and shut

off the engine. Cycle all appropriate controls to relieve
trapped hydraulic pressure.
Use the proper tool for the job. Make sure that jack
stands and lifting equipment are in good condition and of
adequate capacity. Repair or replace worn or damaged
tools, including lifting equipment, before initiating repair
work on your machine.
While servicing or repairing the equipment, shut the

engine down, and disconnect the negative (-) battery
cable from the battery.
2 - 10 M4302001
Section 2

Precautions
WARNING
Never fill the fuel tank with the engine running,
while you, or anyone nearby is smoking or when
near an open flame
Avoid overfilling the tank or spilling fuel. If fuel is spilled,

clean it up immediately.
12691
Ground the fuel funnel or nozzle against the filler neck to
prevent sparks and ensure that the fuel tank filler cap is
reinstalled when fueling is completed.
Do not apply pressure in excess of 5 psi to the fuel tank

or fuel lines.
The fuel system components are not designed to

withstand pressure and can be damaged with
dangerous consequences if pressurized beyond 5 psi.
WARNING
Start the engine from the operator’s seat only.
Never attempt to start the engine by shorting
across the starter terminals.
Do not attempt to start the engine by shorting the starter

circuit across the starter terminals.
M4302001 2 - 11
Section 2

Precautions
WARNING
Never operate an internal combustion
engine without proper ventilation. The exhaust
fumes are poisonous and can kill.
Work in a ventilated area. If it is necessary to run the

engine in an enclosed area, use an exhaust pipe
extension to remove toxic exhaust fumes or open the
shop doors.
Run the engine only when it is necessary for testing or

adjustments.
When welding is required ensure that the battery ground

cable is disconnected and that all electronic equipment
including instruments onboard the machine are totally
isolated electrically before welding is initiated.
Do not weld on the frame, loader, or guards without

obtaining specific consent from the equipment
manufacturer.
Before starting any welding ensure that the area to be

repaired is cleaned of debris and combustible material.
Have a charged fire extinguisher available and know
how to use it.
2 - 12 M4302001
Section 2

Precautions
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate the skin and cause serious personal
injury, blindness, or death. If any fluid is injected
into the skin, it must be surgically removed within a
few hours by a doctor familiar with treating this type
of injury.
NEVER USE YOUR BARE HAND TO CHECK FOR

FLUID LEAKS!
.
Fluid leaks under pressure may not be visible. When
searching for leaks, wear work gloves and use a piece
of cardboard or wood as detector. Wear a safety face
shield or goggles for eye protection.
Pressure can remain in a hydraulic system after the

power source and pump have been shut down.
Therefore, lower the implements to the ground and cycle
all appropriate controls to relieve trapped pressure
before performing work on components, or
disconnecting any hoses.
Do not change any pressure or relief setting unless

authorized instruction has been obtained.
WARNING
Liquid cooling systems build up pressure as the
engine gets hot. Before removing the radiator cap,
stop the engine and let the system cool. Remove
the radiator cap only after the cooling system has
cooled off.
Use extreme caution when draining hot fluids from the

vehicle. Splashing hot fluid can cause serious burns.
M4302001 2 - 13
Section 2

Precautions
WARNING
lead-acid batteries contain sulfuric acid which can
severely damage your eyes or skin on contact.
Always wear a safety face shield, rubber gloves,
and protective clothing to prevent accidents.
Lead-acid batteries produce flammable and

explosive gasses. Keep arcs, sparks, open flames,
and lighted tobacco a safe distance away from the
batteries.
If acid is accidentally splashed into your eyes, flush

immediately with clean water and get medical attention.
Do not attempt to charge a frozen battery; it can explode.
Disconnect the battery before working on the electrical

system. Remove the ground terminal first. When
connecting the battery, connect the ground terminal last.
Do not short out the battery terminals for any reason.

Serious burns or an explosion can result.
Dispose of waste fluids properly. Do not pour

contaminated fluids onto the ground, or into a stream,
pond or lake.
Before draining any fluids, know the proper way to

dispose of them.
Observe local environmental protection regulations

when disposing of used filters, old batteries, waste fuel,
coolant, oil, brake fluid, and other environmentally
harmful items.
2 - 14 M4302001
Section 2
2.7 Transporting On Public

Roads.
When traveling on public roads, use accessory lights
and other cautionary devices to bring your approach to
the attention of other vehicle operators. Ensure that your
vehicle meets all regulatory requirements.
Position and secure the implement attachment, including

the loader, so that the equipment will not move and
cause imbalance during transport.
When transporting the machine ensure that the overall

height does not exceed local or state maximum height
regulation.
2.8 Fire Prevention

When working in a forest environment, it is impossible to
prevent combustible debris from collecting in tight
corners of the machine. This debris, in itself, may cause
a fire; however, when mixed with fuel, oil, or grease in a
hot or confined place, the danger of fire is very much
increased. To reduce the chance of a fire starting,
observe the following instructions:
• Clean dust and debris from the machine regularly.
• Clean the radiator and oil cooler regularly to
ensure components operate at efficient working
temperatures.
• Inspect the machine daily for potential fire hazards
and make any necessary repairs immediately.
• Inspect electrical wiring and connections, fuel and • Store rags and other combustible materials in a
hydraulic hose runs to ensure they are secure and safe, fireproof location.
•
not rubbing against other components.
•
Before starting repair work, such as welding, the
Clean up any excess grease, oil accumulation, and surrounding area should be cleaned and a fire
spillage immediately. extinguisher should be close by.
• Use only nonflammable solutions for cleaning the • Maintain a charged fire extinguisher on the vehicle
machine or components. at all times and KNOW HOW TO USE IT.
M4302001 2 - 15
Section 2
2.9 What to Do If the

Machine Catches Fire
• Turn the engine off.
• Turn the master disconnect switch off
• If possible, fight the fire using the portable fire

extinguisher or other fire suppression equipment.
• Ensure that the fire does not spread to the

surrounding area.
• Call for help!
2 - 16 M4302001
Section 3
10/1996 Theory of Operation
3. Theory of Operation
Not available at the time of publication
M4303001 3-1
.
Section 4
10/1996 Specifications
4. Specifications
4.1 Machine Dimensions - 330 Log Loader 4-2

4.2 Machine Dimensions - 430 Log Loader 4-3
4.3 Equipment Specifications 4-3
4.4 Fluid and Lubricants 4-7
4.5 Torque Values 4 - 14
M4304001 4-1
Section 4
Specifications 10/1996
4.1 Machine Dimensions - 330 Log Loader
A = 99.9" (2537 mm) B = 86.3" (2190 mm) C = 95.6" (2429 mm) D = 40.0" (1016 mm) E = 60.0" (1524 mm) F = 18.8" (476 mm)
G = 164.9" (4188 mm) H = 325.6" (8270 mm) J See Note K = 143.0" (3632 mm) L = 163.0" (4140 mm) M = 34.0" (864 mm)
N = 95.5" (2426 mm) P = 102.0" (2590 mm) Q = 174.8" (4439 mm) R = 183.6" (4664 mm) S = 212.8" (5404 mm) T = 8.8" (224 mm)
U = 48.4" (1229 mm) V = 50.4" (1280 mm)
* Tail Swing
Note:
With optional 29 ft. boom, J = H = 349.7" (8882 mm)
4-2 M4304001
Section 4
4.2 Machine Dimensions - 430 Log Loader
A = 109.3" (2776 mm) B = 97.0" (2464 mm) C = 96.0" (2438 mm) D = 40.0" (1016 mm) E = 60.0" (1524 mm) F = 18.8" (476 mm)
G = 164.9" (4188 mm) H = 359.5" (9131 mm) J Not Applicable K = 143.0" (3632 mm) L = 163.0" (4140 mm) M = 34.0" (864 mm)
N = 95.5" (2426 mm) P = 102.0" (2590 mm) Q = 174.8" (4439 mm) R = 183.6" (4664 mm) S = 212.8" (5404 mm) T = 8.8" (224 mm)
U = 48.4" (1229 mm) V = 50.4" (1280 mm)
* Tail Swing
M4304001 4-3
Section 4
4.3 Equipment Specifications

Engine:
Model . . . . . . . . . . . . . . . . . . . . . . . . . . Cummins 6BTA5.9

No. of cylinders . . . . . . . . . . . . . . . . . . . . . . 6 (Six)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.02 in. (102 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.72 in. (120 mm)
Displacement . . . . . . . . . . . . . . . . . . . . . . . 359 cu.in. (5.90 l)
Rated horsepower . . . . . . . . . . . . . . . . . . . . 174 hp (130 kW) @ 2200 rpm
Rated Max. Torque . . . . . . . . . . . . . . . . . . . . 455 lb.ft. (617 Nm) @ 1500 rpm
Engine:
Model . . . . . . . . . . . . . . . . . . . . . . . . . . Cummins 6BT5.9

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.02 in. (102 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.72 in. (120 mm)
Rated horsepower . . . . . . . . . . . . . . . . . . . . 145 hp (108 kW) @ 2200 rpm
Engine (Optional):
Model . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere 6059T

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19 in. (106.5 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.33 in. (110 mm)
Rated horsepower . . . . . . . . . . . . . . . . . . . . 155 hp (116kW) at 2150 rpm
Electrical Components:
Starter motor
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-28
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt, negative ground
Alternator
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt, 63 Amp, self-energizing
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . Two-12 Volt, group 8D
Fuel, Coolant, and Lubricant Capacity:
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . 75.0 US.gal. (285 litres)

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 US.gal. (22.8 litres)
Engine Crankcase . . . . . . . . . . . . . . . . . . . . 17.3 US.quarts (16.4 litres)
Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . 4.6 US.quarts (4.5 litres)
Main Hydraulic Tank . . . . . . . . . . . . . . . . . . . 100 US.gal. (378 litres)
Lower Hydraulic Tank . . . . . . . . . . . . . . . . . . 65 US.gal. (245 litres)
4-4 M4304001
Section 4

Hydraulic System:
Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . Triple Section Gear Pump

Displacement:
Section I . . . . . . . . . . . . . . . . . . . . . . . . 5.7 cu.in/rev (93 cc/rev)
Section II . . . . . . . . . . . . . . . . . . . . . . . . 5. 1cu.in/rev (83 cc/rev)
Section III . . . . . . . . . . . . . . . . . . . . . . . 3.2 cu.in/rev (53 cc/rev)
Pilot Pump . . . . . . . . . . . . . . . . . . . . . . . . Single gear pump
Nominal Flow . . . . . . . . . . . . . . . . . . . . . . . 5.0 US gpm
SPI Pump (Lower Hydraulic System) . . . . . . . . . . Twin Section Gear Pump

Rated Flow:
MainSection . . . . . . . . . . . . . . . . . . . . . . 80 US gpm (302 l/min)
Pilot Section . . . . . . . . . . . . . . . . . . . . . . 10 US gpm (38 l/min)
Main Boom Cylinders: (2) - Model 330

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 6.00 in. (152 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 37.50 in. (950 mm)
Rod Diameter . . . . . . . . . . . . . . . . . . . . . 3.00 in. (76 mm)
Collapsed Length . . . . . . . . . . . . . . . . . . . 55.00 in. (1392 mm)
Main Boom Cylinders: (2) - Model 430

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 6.00 in. (152 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 44.00 in. (1115 mm)
Jib Boom Cylinder: - Model 330

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 7.00 in. (177 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 37.50 in. (950 mm)
Jib Boom Cylinder: - Model 430

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 7.00 in. (177 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 44.50 in. (1127 mm)
Stabilizer Cylinders: (4)

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . 6.00 in. (152 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 24.00 in. (608 mm)
Joystick Controls: (2)

Operating Pressure . . . . . . . . . . . . . . . . . . 500 psi (3450 kPa)
M4304001 4-5
Section 4

Hydraulic System:
Return Filters:
Main Tank Filters . . . . . . . . . . . . . . . . . . . . Two - 10 micron elements
Lower Tank Filter . . . . . . . . . . . . . . . . . . . One - 10 micron element
Pilot Filter:
In-line Spin-On Filter . . . . . . . . . . . . . . . . . . 10 micron
Bypass Relief Setting . . . . . . . . . . . . . . . . . 50 psi
Main Hydraulic Tank Strainers:

Main Supply Line Strainers . . . . . . . . . . . . . . Two - 100 mesh
Pilot Supply Line Strainer . . . . . . . . . . . . . . . One - 100 mesh
Lower Hydraulic Tank Strainer:

Supply Line Strainers . . . . . . . . . . . . . . . . . One - 100 mesh
Hydraulic Oil Cooler:

Location . . . . . . . . . . . . . . . . . . . . . . . . In Front of Engine Radiator
Swing System:
Swing Drive Gear Box:

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . Single Reduction Planetary
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 42:1
Pinion . . . . . . . . . . . . . . . . . . . . . . . . . 12 Tooth
Swing Gear and Bearing:

Diameter . . . . . . . . . . . . . . . . . . . . . . . . 42 in. (1067 mm)
Turntable Speed . . . . . . . . . . . . . . . . . . . . 7 rpm
4-6 M4304001
Section 4
4.4 Fluids and Lubricants
4.4.1 Fluid and Lubricant Specifications

Location Recommended Lubricant or Fluid Capacity
Cummins Use API classification CD engine oil only. 14.2 litres 15.0 US qt
Engine Crankcase Refer to Paragraph 4.4.2 for appropriate oil
viscosity.
John Deere Use API classification CD engine oil only. 17.0 litres 18.0 US qt
Engine Crankcase Refer to Paragraph 4.4.3 for appropriate oil
viscosity.
Engine Cooling A permanent anti-freeze solution

System (ethylene glycol base) as a year
round fill.
Cummins 6BT Recommended mixture: 25.0 litres 26.4 US qt
Engine 40% anti-freeze to 60% clean water.
Cummins 6BTA 27.0 litres 28.5 US qt

Engine
John Deere 29.5 litres 31.2 US qt

Engine
Hydraulic System Quality hydraulic fluid.

Refer to Paragraph 4.4.5 and 4.4.6 for
characteristics and recommended fluids.
Main Reservoir 378 litres 100 US gal
When changing hydraulic fluid, select a
brand that is readily available and suitable
for the ambient temperatures at which the
Lower Reservoir loader is operated. 245 litres 65.0 US gal
The main hydraulic system is factory filled

with Esso Univis N68 and the lower hydraulic
system with Esso Univis N32 hydraulic fluid.
Swing Drive Planetary EP gear oil to MIL-L-2105C Specifications 6.8 litres 7.2 US qt
(API GL-5 service designation).
Refer to Paragraph 4.4.4 for appropriate
oil viscosity.
M4304002 4-7
Section 4
Specifications
4.4.1 Fluid and Lubricant Specifications

Location Recommended Lubricant or Fluid Capacity
Fuel Tank A.S.T.M. designation D-975 284 litres 75.0 US gal

Below 0o C. (32o F) No. 1-D
Above 0o C. (32o F) No. 2-D
Note!
The cloud point of the fuel should always
be 6o C. (10o F) lower than the ambient .
temperature to prevent wax crystals
from clogging the filters.
General Greasing Good quality multi-purpose As Required

EP grease with 3% molybdenum disulfide.
4-8 M4304002
Section 4
4.4 Fluid and Lubricants
4.4.2 Engine Oil Viscosity - Cummins
SAE 15W - 40
100 oF 38 oC
10 oF - 12 oC
SAE 10W - 30
- 15 oF - 26 oC
SAE 5W - 30
- 40 oF - 40 oC
12308
4.4.3 Engine Oil Viscosity - John Deere
SAE 15W - 40
122 oF 50 oC
SAE 40
104 oF 40 oC
SAE 10W - 30 SAE 30
86 oF 30 oC
SAE 5W - 30 68 oF 20 oC
SAE 10W
50 oF 10 oC
32 oF 0 oC
Arctic Oil 14 oF - 10 oC
5 oF - 15 oC
-4 oF - 20 oC
- 22 oF - 30 oC
12312
- 67 oF - 55 oC
M4304002 4-9
Section 4
Specifications
4.4 Fluid and Lubricants
4.4.4 Gear Oil Viscosity - Swing Drive Gearbox
SAE 85W - 140 EP SAE 80W - 140 EP
SAE 80W - 90 EP SAE 75W - 90 EP*

100 oF 38 oC
10 oF - 12 oC
- 15 oF - 26 oC
- 40 oF - 40 oC
12309
* Factory Fill
4 - 10 M4304002
Section 4
4.4.5 Hydraulic Lubrication and Fluid recommendation

In the hydraulic system all parts, with the exception of Filtration:
the pump and motor outboard bearings, are lubricated 10 micron recommended for maximum pump life.
by the hydraulic fluid in the system. Therefore; particular
attention should be paid to keep this fluid clean. Other Desirable Characteristics:
Whenever there is a component failure, and there is Stability of physical and chemical characteristics.
reason to suspect that metal particles may be High demulsibility (low emulsibility) for separation of
contaminating the system, the fluid should be drained, water, air, and contaminants.
the entire system flushed clean, and any filter screens Resistant to the formation of gums, sludge, acids, tars,
thoroughly cleaned or replaced. Fresh fluid should be and varnishes.
supplied for the entire system. Fluid suitable and High lubricity and film strength.
recommended for use in the loader hydraulic system
should meet the following specifications: General Recommendations:
A good quality hydraulic fluid conforming to the
Viscosity: characteristics listed above is essential to satisfactory
•50 SSU minimum @ operating temperature performance and long life of the hydraulic system.
7500 SSU maximum @ starting temperature
•150 to 225 SSU @ 100o F (37.8o C)(generally) The fluid should be changed at regular scheduled
44 to 48 SSU @ 210o F (98.9o C) (generally) intervals and the system flushed periodically as detailed
in the Operator, Maintenance and Specification Manual.
Approximate SSU at... The fluid temperature in the reservoir should not exceed
Oil Grade 100o F (37.8o C) o o
210 F (98.9 C) 200o F (93.3o C) with a maximum temperature of 180o F
(82.2o C) recommended. Higher temperatures will result
SAE 10 150 43
in rapid fluid deterioration.
SAE 20 330 51
Fluid poured into the reservoir should pass through a
Viscosity Index: 100 mesh screen. Pour only clean, fresh fluid from clean
90 minimum containers into the reservoir.
Aniline Point: Normal Temperatures:

175 minimum 0o F (-18o C) to 100o F (37.8o C) Ambient
100o F (37.8o C) to 180o F (82.2o C) System
Recommended Additives: Ensure that your fluid is recommended for the
Foam depressant, rust and oxidation inhibitors. temperatures you expect to encounter.
M4304002 4 - 11
Section 4
Specifications
4.4.5 Hydraulic Lubrication and Fluid recommendation

Cold Weather Operation: Diesel Fuel or Kerosene (Coal Oil) sometime being used
Fluids used in cold weather should have a viscosity not as dilutants for cold weather operations are not
exceeding 7500 SSU at the minimum start-up recommended as they are not sufficiently refined
temperature. A pour point of at least 20o F (7o C) below products.
the start-up temperature is recommended. The start-up
procedures should allow for a gradual warm-up until the Fire Resistant Fluids: DO NOT USE ANY FIRE
fluid reaches a reasonable fluid state. RESISTANT FLUIDS OR NON-PETROLEUM OILS AT
ALL.
The Use of Other Fluids:
Automatic Transmission Fluid (ATF): Experience With The above suggestions are intended as a guide only.
this type of fluid has been satisfactory; however, ATF Refer to Paragraph 4.4.6 for recommended fluid brands
fluids are often too expensive for normal use as or obtain final fluid recommendations from your fluid
hydraulic fluid. supplier.
4 - 12 M4304002
Section 4
4.4.6 Recommended Hydraulic Fluids Brands

ISO Viscosity Supplier Brand Name Ambient Operating Temperature
Grade Minimum Maximum
15 -34oC (-29oF) 29oC (84oF)

Esso Univis N15
Petro Canada Harmony Arctic 15
Gulf Harmony Arctic 15
Mobil DTE 11M
Shell Tellus T15
Texaco Rando Superflo 15
Texaco Rando HDZ 15
22 -26oC (-15oF) 43oC (109oF)

Esso Univis N22
Petro Canada Harmony HVI 22
Gulf Harmony HVI 22
Shell Tellus T22
Texaco Rando Superflo 22
Texaco Rando HDZ 22
32 -18oC (0oF) 46oC (115oF)

Amsoil Synthetic Hydraulic Fluid
* Esso Univis N32
Petro Canada Harmony HVI 36
Gulf Harmony HVI36
Mobil DTE 13M
Shell Tellus T32 or Tellus 32
Texaco Rando Superflo AZ
Texaco Rando HDZ 32
46 -7oC (19oF) 46oC (115oF)

Arco Duro AW46
Chevron HYD AW46
Petro Canada Harmony AW46
Gulf Harmony AW46
Mobil DTE 15M
Shell Tellus 46
Texaco Rando HDZ 46
68 -2oC (28oF) 46oC (115oF)

* Esso Univis N68
Texaco Rando HDZ 22
* Factory fill. See Paragraph 4.4.1
M4304002 4 - 13
Section 4
4.5 Torque Values
4.5.1 Steel Fasteners
Scope
This Standard applies to steel cap screws engaged with
The following torque values should be used in general steel female thread and is applicable for all thread
applications and where torque values are not otherwise pitches. Torque values for other materials are to be
specified. specified on the drawings where needed.
Fastener Markings
Grade 8 - Imperial
Class 10.9 - Metric
Class 12.9 - Metric
M4304003 4 - 14
Section 4
4.5 Torque Values

Imperial Hex Head
Tightening Torque Values for Grade 8
Nominal Thread Diameter

Nm lb ft
Min Max Min Max
1/4 0.2500 12 14 9 10
5/16 0.3125 24 27 18 20
3/8 0.3750 50 55 34 40
7/16 0.4375 80 90 60 65
1/2 0.5000 125 135 90 100
9/16 0.5625 170 190 125 140
5/8 0.6250 240 255 175 190

3/4 0.7500 405 455 300 330
7/8 0.8750 645 710 475 525
1 1.000 985 1085 725 800

1 1/8 1.125 1425 1595 1050 1175
1 1/4 1.250 2000 2205 1475 1625
1 3/8 1.375 2710 2980 2000 2200

1 1/2 1.500 3525 3865 2600 2850
1 5/8 1.625 4680 5150 3450 3800
1 3/4 1.750 5850 6510 4300 4800

1 7/8 1.875 8270 7460 5500 6100
2 2.000 8810 9760 6500 7200
4 - 15 M4304003
Section 4
4.5 Torque Values

Metric Hex Head
Tightening Torque Values
Norminal Thread Class 10.9 Class 12.9

Diameter
Nm Ib ft Nm lb ft
Min Max Min Max Min Max Min Max
M5 7 8 5 6 8 9 6 7
M6 12 14 9 10 14 16 10 12
M8 30 35 22 24 35 40 25 28
M10 55 65 42 48 65 75 50 56
M12 100 115 75 85 120 135 85 100
M14 165 185 120 135 190 210 140 155
M16 250 285 185 210 290 330 215 245

M20 490 550 360 405 570 645 420 475
M22 665 745 490 550 775 875 570 645
M24 840 950 620 700 1000 1125 725 820

M30 1700 1900 1250 1400 1950 2200 1450 1625
M36 2900 3300 2150 2450 3425 3850 2525 2850
M42 4675 5250 3450 3900 5500 6150 4050 4550

M48 7050 7900 5200 5800 8200 9200 6050 6800
M4304003 4 - 16
Section 4
4.5 Torque Values
Metric Flanged Hex Head
Tightening Torque Values for

Class 10.9
Nominal Thread Diameter
Nm lb ft
Min Max Min Max
M5 7 8 5 6
M6 12 15 9 11
M8 32 38 23 26
M10 60 70 45 50
M12 110 125 80 90
M14 170 190 125 140
M16 265 300 195 220

M20 515 575 380 425
M22 665 745 490 550
M24 840 950 620 700
Notes!
1. Torque values shown are based on zinc phosphate or oil coating.
2. The torque values listed develop clamping forces that are based on material proof loads for the different class
fasteners. The clamping forces developed are 85 ± 5% of proof loads.
3. All the torque values in Nm or lb ft are rounded to the nearest multiple of 5 or in some cases to the nearest whole
number to be in line with graduations on torque wrenches and dials.
CAUTION
Use only metric tools on metric hardware and imperial tools on imperial hardware to assure correct torque
readings and to prevent damage to tools and hardware, and possible personal injury.
4 - 17 M4304003
Section 4
4.5 Torque Values
4.5.2 Hydraulic Fittings

Scope
This standard establishes torques for tightening of hydraulic fittings of various types in use on Timberjack Inc. forestry
machines.
O-Ring Type Fittings
All O-Rings should be lightly coated with hydraulic fluid before installation. Tighten the fittings to the torque values
specified in the following chart.
O-Ring Face Seal End O-Ring Boss End
.
Thread Swivel Nut Nominal SAE Thread Straight Fitting or
Size Torque Dash No Size Locknut Torque
Nm lb ft Nm lb ft
9/16 - 18 14-16 10-12 -4 7/16 - 20 20-22 14-16

11/16 - 16 24-27 18-20 -6 9/16 - 18 33-35 24-26
13/16 - 16 43-47 32-35 -8 3/4 - 16 68-78 50-60
1 - 14 60-68 46-50 - 10 7/8 - 14 98-110 72-80

1 3/16 - 12 90-95 65-70 - 12 1 1/16 - 12 170-183 125-135
1 3/16 - 12 90-95 65-70 - 14 1 3/16 - 12 215-245 160-180
1 7/16 - 12 125-135 92-100 - 16 1 5/16 - 12 270-300 200-220

1 11/16 - 12 170-190 125-140 - 20 1 5/8 - 12 285-380 210-280
2 - 12 200-225 150-165 - 24 1 7/8 - 12 370-490 270-360
Ref.: SAE J1453 Jun94
M4304003 4 - 18
Section 4
4.5 Torque Values

SAE Code 61 and Code 62 Flanges
For both one piece and split flanges turn the bolts until mating parts are in full contact.. Tighten one bolt, then the
opposite, followed by the other two before applying torque.
Flange Flange Code 61 - Standard Pressure Series Code 62 - High Pressure Series
Size Dash No.
Torque Bolt Torque Bolt

lb ft Nm Thread lb ft Nm Thread
1/2 - 08 15 - 19 20 - 25 5/16 - 18 15 - 19 20 - 25 5/16 - 18

3/4 - 12 21 - 30 28 - 40 3/8 - 16 25 - 34 34 - 45 3/ 8 - 16
1 - 16 27 - 36 37 - 48 3/8 - 16 42 - 50 56 - 68 7/16 - 14
1 1/4 - 20 35 - 46 48 - 62 7/16 - 14 63 - 75 85 - 102 1/2 - 13

1 1/2 - 24 46 - 59 62 - 79 1/2 - 13 117 - 134 158 - 181 5/8 - 11
2 - 32 54 - 67 73 - 90 1/2 - 13 271 - 294 200 - 217 3/4 - 10
2 1/2 - 40 79 - 92 107 - 124 1/2 - 13

3 - 48 138 - 150 186 - 203 5/8 - 11
Ref. SAE J518 Jun93
Tapered Pipe Threads (NPTF & NPT)
Pipe Dash Threads with sealant Pipe Dash Threads with sealant
Thread No. lb ft Nm Thread No. lb ft Nm
1/8 - 27 - 02 15 20 1 - 11 1/2 - 16 55 75
1/4 - 18 - 04 18 25 1 1/4 - 11 1/2 - 20 70 95
3/8 - 18 - 06 26 35 1 1/2 - 11 1/2 - 24 81 110
1/2 - 14 - 08 33 45 2 - 11 1/2 - 32 96 130

3/4 - 14 - 10 44 60
4 - 19 M4304003
Section 4
4.5 Torque Values

Flare Fittings
1. Check flare and seat for defects that might cause leakage and lubricate the connection with system fluid.
2. Install hoses without twist.
3. When a torque wrench cannot be used, tighten until seats bottom.

Using two wrenches to prevent twisting, rotate the nut the number of hex flats or equivalent shown below.
Torque and Turn Flats for Tightening Flare Fittings
Tube Tube 37o Flare Number of Flats

O.D. Dash Thread
Inches No. Size lb ft Nm New Re-assy
3/16 - 03 3/8 - 24 4-5 5-7 2 1/2 1

1/4 - 04 7/16 - 20 9 - 10 12 - 14 2 1/2 1
5/16 - 05 1/2 - 12 15 - 17 20 - 23 2 1/2 1
3/8 - 06 9/16 - 18 20 - 22 27 - 30 2 1
1/2 - 08 3/4 - 16 30 - 33 41 - 45 2 1
5/8 -10 7/8 - 14 40 - 44 54 - 60 1 1/2 - 2 1
3/4 - 12 1 1/16 - 12 70 - 77 95 - 104 1 3/4

7/8 - 14 1 3/16 - 12 82 - 90 111 - 122 1 3/4
1 - 16 1 5/16 - 12 90 - 99 122 - 134 3/4 3/4
1 1/4 - 20 1 5/8 - 12 120 - 132 163 - 179 3/4 3/4

1 1/2 - 24 1 7/8 - 12 131 - 144 178 - 195 1/2 1/2
2 - 32 2 1/2 - 12 300 - 330 407 - 447 1/2 1/2
M4304003 4 - 20
Section 5
10/1996 Test Procedures and Adjustments
5. Tests Procedures
and Adjustments
5.1 General Information 5-3

5.2 Hydraulic Systems 5-4
5.3 Electrical System 5 - 17
M4305001 5-1
Section 5
5.1 General Test Information
5.1.1 Hydraulic Tests Important!

Cap hydraulic ports, hoses, and fittings immediately
The test equipment selected to perform the tasks after disconnecting in order to prevent the components
detailed in the following paragraphs must be adequate in from becoming contaminated. Contamination introduced
terms of range, accuracy and reliability. Whether digital into the hydraulic system can lead to premature
electronic equipment or analog hydraulic gauges are equipment failure
used when performing hydraulic test procedures is not
important; however, the performance of the machine, Important!
once the test and adjustment procedures are completed, Unless otherwise specified, all hydraulic pressure tests
is of great importance. Therefore, execute the test and must be performed with the hydraulic fluid at normal
adjustment procedures carefully and ensure that the operating temperature (approximately 150 oF (62 oC)).
results obtained closely match the figures outlined in the
procedures.
5.1.2 Electrical Tests
WARNING Generally a multimeter and simple continuity testing
Hydraulic fluid under pressure can penetrate the components are used for fault locating, testing and
skin and cause serious personal injury, blindness, adjusting the electrical circuits and components on the
or death. If any fluid is injected into the skin, it must loader. Special test equipment, beyond what is normally
be surgically removed within a few hours by a available at most repair and maintenance facilities, is not
doctor familiar with treating this type of injury. required.
M4305002 5-3
Section 5
Test Procedures and Adjustments 10/1996
5.2 Hydraulic System
5.2.1 Main Control Valve

5.2.1.1 Main Relief
Locate the main relief (1) and the pressure test port (2)
on the main control valve. Install a pressure gauge with
an appropriate range onto the test port.
With the engine at full throttle operate the grapple

valve (3) to close the grapple (4).
Maintain the grapple valve in closed position and note

the pressure at the test port. This pressure should be:
Model 330 SPI an Swivel Machines: 2300 psi (159 bar).
Loosen jam nut (5) on the end of the relief valve and
adjust the relief valve cartridge as needed.
Turn the relief valve cartridge clockwise to increase and

counterclockwise to reduce the relief pressure.
Tighten the jam nut when the adjustment is completed,

reduce the engine speed to idle and remove the gauge
from the test port.
5-4 M4305002
Section 5
5.2.1 Main Control Valve

5.2.1.2 Main Boom Port Reliefs
Locate the main boom port reliefs (A and B) and the test
port (1). Install a pressure gauge with an appropriate
range onto the test port.
With the engine at 1000 rpm, operate the main boom

valve (2) to lower the main boom.
Maintain the control valve in this position and note the

pressure at the test port. This pressure should be:
Model 330 SPI and Swivel Machines: 2200 psi (152 bar).
Loosen jam nut (4) on the end of relief valve (A) and
Turn the relief valve cartridge clockwise to increase or

counterclockwise to reduce the relief pressure. Tighten
the jam nut once the adjustment is completed.
Loosen the jam nut on the end of relief valve (B) and
back off the relief valve cartridge approximately two full
turns.
With the engine at 1000 rpm, operate the control valve to

lift the main boom.
Maintain the main boom at maximum lift while adjusting

the relief valve cartridge to:
Then turn the relief valve cartridge clockwise an
additional 1/4 turn.
Note!
Although not directly measurable, the additional 1/4 turn
increases the relief pressure with 500 psi (34,5 bar).

from the test port.
M4305002 5-5
Section 5
5.2.2 Jib Valve - Boom Section

5.2.2.1 Main Relief
Locate the main relief (1) and the test port (2) on the jib
control valve. Install a pressure gauge with an
appropriate range onto the test port.
With the engine at full throttle operate the jib valve (3) to
move the jib boom (4) in.
Maintain the jib valve in this position and note the relief
pressure at the test port. This pressure should be:


from the test port.
5-6 M4305002
Section 5
5.2.2 Jib Valve - Boom Section

5.2.2.2 Jib Boom Port Reliefs
Locate the jib boom port reliefs (A and B) and the test
port (1) on the jib control valve. Install a pressure gauge
with an appropriate range onto the test port.
With the engine at 1000 rpm, operate the jib boom

valve (2) to move the jib boom (3) in.
Maintain the valve in this position and note the relief

pressure at the test port. The pressure should be:
Loosen jam nut (4) on the end of relief valve (A) and

the jam nut when the adjustment is completed.
Loosen jam nut on the end of relief valve (B) and back
off the relief valve cartridge approximately two full turns.
With the engine at 1000 rpm, operate the control valve

to move the jib boom (3) out.
Maintain the jib boom in maximum out position while

adjusting the relief valve cartridge to:
Then turn the relief valve cartridge clockwise an
additional 1/4 turn.
Note!
Although not directly measurable, the additional 1/4 turn
increases the relief pressure with 500 psi (34.5 bar).

from the test port..
M4305002 5-7
Section 5
5.2.3 Jib Valve - Swing Section

5.2.3.1 Main Swing Relief
Note!
When testing the main swing relief, either one of the two
test ports at the swing motor ports may be used for
measuring the relief pressure.
Locate the main swing relief (1) on the jib control valve
and one of the two the test ports (2) at the swing motor.
Install a pressure gauge with an appropriate range onto
the test port.
Restrain the loader so that the turntable can not turn

and, with the engine at full throttle, operate the swing
valve (3) to engage the swing motor (4) in either
clockwise or counterclockwise direction.
Maintain the swing valve engaged while noting the relief

pressure at the test port. This pressure should be
2400 psi (165 bar).

Tighten the jam nut securely once the correct pressure

is obtained, release the swing valve, reduce the engine
rpm to idle and remove the test port gauge.
5-8 M4305002
Section 5

5.2.3.3 Swing Motor High Pressure
Crossover Relief
Note!
The crossover high pressure relief should always be
checked and, if necessary, adjusted before the low
pressure relief is adjusted.
Locate the main swing relief (1) on the jib control valve,
loosen the jam nut (2) on the end of the relief valve and
turn the valve cartridge all the way clockwise.
Locate the two pressure test ports (3) at the swing

motor. Install a pressure gauge with an appropriate
range onto each of the two test ports.
Restrain the loader turntable so that no turning is

possible and, with the engine operating at full throttle,
operate the swing valve (4) to engage the swing
motor (5) in either clockwise or counterclockwise
direction.
Maintain the swing valve engaged and note the pressure

at the test port being pressurized. This pressure should
be 2550 psi (176 bar).
M4305002 5-9
Section 5
5.2.3 Jib Valve - Swing Section Note!

The following adjustment procedure is applicable to both
5.2.3.3 Swing Motor High Pressure of the two crossover relief cartridges.
Crossover Relief Cont.
Remove the relief valve cartridge from the crossover
valve and disassemble the cartridge as shown.
Add or subtract shims from the shim pack (9) to obtain a

higher or lower relief pressure as needed.
Ensuring that poppet (8) is correctly seated, reassemble

the relief valve cartridge. Torque the connection of
poppet seat (7) and cartridge body (11) to 25 to 30 lb ft
(34 to 41 Nm).
Install the relief valve cartridge onto the crossover valve

and connect the pilot hose to the cartridge.
Repeat the pressure test to ensure that the relief setting

is as required.
Engage the swing valve to the opposite direction of

rotation and check the pressure at the second test port.
This pressure should also be 2550 psi (176 bar).
7. Poppet Seat Adjust the second relief valve in the same fashion as the
8. Poppet first.
9. Shim Pack
10. Spring Remove the gauges and recap the test ports when tests
11. Cartridge Body and adjustments are completed.
5 - 10 M4305002
Section 5

5.2.3.2 Swing Motor Low Pressure
Crossover Relief
Note!
The crossover high pressure relief should always be
checked and, if necessary, adjusted before the low
pressure relief is adjusted.
Locate the swing motor crossover relief pilot line

junction (1) and disconnect the feed line from the
junction. Cap both the feed line and the tee fitting
immediately to avoid spill and prevent contamination.
Note!
On machines equipped with two separate feed lines
both lines should be disconnected.
Install a pressure gauge with an appropriate range onto

each of the two test ports (2) on the swing motor.
Restrain the loader such that no turning is possible and,

with the engine at full throttle, operate the swing
valve (3) to attempt to turn the swing motor (4) in one
direction.
Maintain the swing valve engaged and note the relief

pressure at the test port. This pressure should
be 1450 psi (100 bar).
Loosen the jam nut (5) on the end of the relief valve
cartridge (6) and adjust the cartridge insert (7) as
needed. Turn the cartridge insert clockwise to increase
or counterclockwise to reduce the relief pressure.
Torque the jam nut to 25 to 30 lb ft (34 to 41 Nm) when

the adjustment is completed.
Engage the swing valve to rotation in the opposite

direction and check the pressure at the second test port.
This pressure should also be 1450 psi (100 bar). Lower the engine speed to idle and reconnect the
crossover relief pilot line(s) when the test and
Loosen the jam nut on the end of the second relief valve adjustment procedure is completed.
cartridge and adjust the relief pressure in similar fashion
to the first.
M4305002 5 - 11
Section 5
5.2.4 Pilot Relief

Locate the pilot pressure relief valve (1) on the rear face
of the turntable frame and install a pressure gauge with
an appropriate range onto the test port (2).
With the engine at full throttle and no functions operated,

the pressure at the test port should be 500 psi (34.5 bar).
Loosen jam nut (3) on the relief valve cartridge stem and
turn the hex cap (4) to adjust the relief valve.
Turn the hex cap clockwise to increase and

Stop the engine, remove the gauge from the test port,
install the protective cap on the port fitting and tighten
the jam nut (3) against the hex cap (4) when the test and
adjustment is completed.
5 - 12 M4305002
Section 5
5.2.5 Delimber Valve Pressure Relief

(Swivel Machines)
Locate the delimber valve (1) and detent valve (2) and
install a pressure gauge with an appropriate range onto
the test port (3).
With the power beyond ports (delimber and saw) on the

loader base frame capped and the engine at full throttle,
operate the delimber valve section (4) to "open" the
delimber knives.
3
Maintain the delimber valve section in "open" position
and note the relief pressure shown at the test port. This 2
pressure should be 1600 psi (130 bar).
If the measured pressure is within ± 10% of the nominal

pressure, the relief valve (5) is acceptable; however, if
the measured test result exceeds ± 10% and no other
component(s) is faulty, the relief valve should be
replaced.
M4305002 5 - 13
Section 5
5.2.6 SPI Bar Saw Valve Main Relief

Locate the SPI bar saw valve (lower control valve) (1) in
the loader base frame and install a pressure gauge with
an appropriate range onto the test port (2).
Note!
Any of the four stabilizers may be used to perform this
test. The function referenced in the illustrations is the left
front stabilizer.
With the engine at full throttle, operate one of the

stabilizer valve sections (3) to extend the stabilizer
cylinder.
While maintaining the extend function engaged, check

the main relief pressure at the test port gauge. This
pressure should be 2000 psi (137.5 bar).
Loosen jam nut (4) on the end of relief valve (5) and

the jam nut securely once the adjustment is completed.
5 - 14 M4305002
Section 5
5.2.7 SPI Pilot Priority Flow

Remove the pilot line (1) and connect the input hose of
an appropriate flow meter gauge to the priority valve
fitting (2).
Disconnect the tank return hose (3) from the priority

valve and install an appropriate size tee-fitting (4) onto
the elbow fitting.
Connect the flow meter outlet line and the tank return
hose to the tee-fitting.
Loosen the jam nut (5) on the adjustable flow

control (6).
With the engine at full throttle, operate the SPI pump

while checking the flow meter.
Adjust the flow control adjustment screw until a steady

flow of 4 gpm (15 l/m) is obtained. Tighten the jam nut
(5) securely when the adjustment is completed.
Disengage the SPI pump drive and lower the engine

speed to idle.
Remove the test equipment and reinstall the hydraulic

hoses onto the priority valve. Check for leaks.
M4305002 5 - 15
Section 5
5.2.8 SPI Pilot Priority Relief

Note!
The pilot priority relief valve is pre-set by the OEM
manufacturer to 450 psi +100 / -50 psi
(31 +6.9 / -3.5 bar) at a flow of 4.0 gpm (15 l/m).
Locate the pilot pressure relief valve (1) on the SPI

pump priority valve and install a pressure gauge with an
appropriate range onto the test port (2).
With the engine operating at full throttle and no functions

operated, the pressure at the test port should be 450 psi
(31 bar).
If the measured pressure is within +100 / -50 psi

(+6.9 / -3.5 bar) of 450 psi (31 bar), the relief valve is
acceptable; however, if the measured test result is
outside this tolerance area and no other component(s) is
faulty, the relief valve should be replaced.
5 - 16 M4305002
.
Section 6
10/1996 Hydraulic Systems
6. Hydraulic Systems
6.1 Hydraulic System Schematic - SPI 6-2

6.2 Hydraulic System Schematic - Swivel 6-4
M4306001 6-1
Section 6
Hydraulic Systems 10/1996
6.1 Hydraulic System Schematic - SPI

Legend
Model 330 Model 430
1. Grapple
2. Grapple cylinders (two)
3. Grapple rotator, continuous rotation
4. Main boom cylinders (two) 6.00 in. (152.4 mm) bore. 6.00 in. (152.4 mm) bore.
3.00 in. (76.2 mm) rod dia. 3.00 in. (76.2 mm) rod dia.
37.5 in. (954 mm) stroke. 44.0 in. (1118 mm) stroke.
5. Jib cylinder (two) 7.00 in. (152.4 mm) bore. 7.00 in. (152.4 mm) bore.
6. Swing motor
7. Crossover relief valve
Low pressure: 1450 psi @ 30 US gpm (9990 kPa @ 114 l/min)
High pressure: 2550 psi @ 30 US gpm (17570 kPa @ 114 l/min)
8. Main Valve
9. Relief valve.
Set at full throttle: 2300 psi (15850 kPa)) 2500 psi (17225 kPa)
10. Grapple cylinders
11. Main boom
12. SPI drive
13. Check valve
14. Jib valve
15. Relief valve
Set at full throttle: 2300 psi (15850 kPa) 2500 psi (17225 kPa)
16. Jib cylinders
17. Grapple rotator
18. SPI drive
19. Swing motor
20. Swing relief valve. Set at 2400 psi (16535 kPa)
21. Check valve
22. Left joystick***
23. Grapple close
24. Main boom up
25. Grapple open
26. Main boom down
27. Right joystick***
28. Grapple rotate, clockwise
29. Jib boom up
30. Grapple rotate, counterclockwise
31. Jib boom down
32. SPI drive pilot valve
33. Oil cooler, 65 psi (448 kPa) by-pass relief
34. Tripple section main pump
35. Section 1. - 55 US gpm (208 l/min). Displacement: 5.7 cu.in./rev (93 cc/rev)
38. Hydraulic filter, 50 psi ( 345 kPa) by-pass relief
6-2 M4306001
39. Pilot relief valve, 500 psi (345 kPa) relief setting
40. Pilot pump
41. Upper hydraulic tank
42. Return filter, 25 psi (172 kPa) by-pass relief (two)
43. Strainer, 100 mesh, 3 psi (21kPa) by-pass relief (two)
44. Strainer, 100 mesh, 3 psi (21 kPa) by-pass relief
45. Shut-off valve, 1 in. ball
47. SPI motor
48. Dual section SPI pump
49. Main pump section - 75 US gpm (284 l/min)
50. Pilot pump section - 10 US gpm (38 l/min)
51. Priority valve, 450 psi @ 4 US gpm (3100 kPa @ 15 l/min)
52. Bar saw valve
53. Relief valve. Set at 2000 psi (13780 kPa)
54. Left front stabilizer
55. Left rear stabilizer
56. High volume remote
57. Right rear stabilizer
58. Right front stabilizer
59. Stabilizer cylinder (four) - 6.00 in. (152.4 mm) bore.
3.00 in. (76.2 mm) rod diameter.
24.0 in. (610 mm) stroke.
60. Cross piloted valve (four)
61. Power beyond connections
62. Saw and bar down
63. Bar up
64. Return
65. Lower hydraulic tank
66. Return filter, 25 psi (172 kPa) by-pass relief
67. Strainer, 100 mesh, 3 psi (21 kPa) by-pass relief
AS. A-side
BS. B-side
TP. Test port
A. A port
B. B port
P. Pressure in
T. Tank return
Note!
* Set port relief valve as follows.
Model 330: 2200 psi (15170 kPa) at 1000 rpm
** Set port relief valve as follows.
Model 330: 2100 psi (14480 kPa) at 1000 rpm and advance adjusting screw clockwise 1/4 turn.
*** Disregard joystick functions on machines equipped with manual control valve levers.
Section 6
6.2 Hydraulic System Schematic - Swivel

Legend
Model 330 Model 430
1. Grapple
2. Grapple cylinders (two)
3. Grapple rotator, continuous rotation
4. Main boom cylinders (two) 6.00 in. (152.4 mm) bore. 6.00 in. (152.4 mm) bore.
5. Stabilizer cylinder (four) - 6.00 in. (152.4 mm) bore.
3.00 in. (76.2 mm) rod diameter.
24.0 in. (610 mm) stroke.
6. Cross piloted valve (four)
7. Stabilizer manifold
8. Jib cylindeer (two) 7.00 in. (152.4 mm) bore. 7.00 in. (152.4 mm) bore.
3.50 in. (89 mm) rod dia. 3.50 in. (89 mm) rod dia.
9. Swing motor
10. Crossover relief valve
Low pressure: 1450 psi @ 30 US gpm (9990 kPa @ 114 l/min)
High pressure: 2550 psi @ 30 US gpm (17570 kPa @ 114 l/min)
11. Main Valve
12. Relief valve.
13. Left front stabilizer
14. Left rear stabilizer
15. Grapple cylinders
16. Main boom
17. Jib valve
18. Relief valve
19. Jib cylinders
20. Grapple rotator
21. Right rear stabilizer
22. Right front stabilizer
23. Swing motor
24. Swing relief valve. Set at 2400 psi (16535 kPa)
25. pilot stabilizer valve
26. Left joystick***
27. Grapple close
28. Main boom up
29. Grapple open
30. Main boom down
31. Right joystick***
32. Grapple rotate, clockwise
33. Jib boom up
34. Grapple rotate, counterclockwise
35. Jib boom down
36. Hydraulic filter, 50 psi ( 345 kPa) by-pass relief
37. Pilot relief valve, 500 psi (345 kPa) relief setting
38. Pilot pump
39. Tripple section main pump
43. Oil cooler, 65 psi ( ) by-pass relief
44. Hydraulic tank
45. Return filter, 22 psi (152 kPa) by-pass relief (two)
46. Strainer, 100 mesh, 3 psi (21kPa) by-pass relief
47. Strainer, 100 mesh, 3 psi (21kPa) by-pass relief (two)
48. Tank breather, pressure and vacuum relief.
Relief pressure: 10 psi (70 kPa)
Vacuum relief: 1 psi (7 kPa).
49. Pressure differential switch. Set at 18 psi (124 kPa)
50. Shut-off valve, 2 in. ball (two)
52. Delimber valve
53. Relief valve. Set at 1600 psi (11025 kPa)
54. Delimber knives
55. Saw
56. Delimber pilot valve
57. Detent valve
58. Diverter valve
59. Power beyond connections
61. Bar up
62. Return
63. Return
64. Bar up
66. Delimber knives
AS. A-side
BS. B-side
PB. Power beyond
SW. Swivel
TP. Test port
A through H. Valve ports
(1) through (9). Swivel ports
P. Pressure in
T. Tank return
Note!
* Set port relief valve as follows.
** Set port relief valve as follows.
*** Disregard joystick functions on machines equipped with manual control valve levers.
6-4 M4306001
Section 7
10/1996 Electrical Systems
7. Electrical Systems
7.1 Electrical Schematic - SPI 7-2

7.2 Electrical Schematic - Swivel, Joysticks 7-4
7.3 Electrical Schematic - Swivel, Lever Controls 7-6
M4307001 7-1
Section 7
Electrical Systems
7.1 Electrical Schematic - SPI
Legend
1. Ignition Switch 36. Relay, accessories
2. Accessories 37. Circuit breaker, 15 Amp
3. Run 38. Wiper motor
4. Start 39. Washer pump switch
5. Starter relay
6. Starter solenoid 40. Washer pump
7. Starter motor 41. Horn switch
8. Batteries (two) 42. Horn
9. Master disconnect switch 43. Heater fan switch
10. Run relay Off
11. Dome light L - low
12. Recirculation fan H - high
13. Fuel Solenoid 44. Heater fan motor
14. Alternator 45. Electric swivel
15. Resistor 46. Switch, left rear stabilizer
16. Tachometer 47. Switch, left front stabilizer
17. Water temperature gauge 48. Switch, saw
18. Water temperature sender 49. Switch, Delimber knives
19. Engine oil pressure gauge 50. Switch, right front stabilizer
20. Engine oil pressure sender 51. Switch, right rear stabilizer
21. Voltmeter 52. Stabilizer valve solenoid (10)
22. A/C relay 53. Solenoid valve
23. Circuit breaker, 25 Amp (two) 54. Wire numbers used
24. Dome light 55. Connector locations
25. Fan switch
Off BL - Blue
L - low OR - Orange
M - medium RE - Red
H - high
26. A/C on/off switch CR - Diode
27. Thermostat
28. Binary switch CL - Close
29. Motor (evaporator) OP - Open
30. Control relay No. 1
31. Condenser motor UP - Up
32. Control relay No. 2 DN - Down
33. Compressor clutch
34. Relay, lights L1 and L2 - Terminal blocks in control panel for lights
35. Wiper switch
P - pulse
L - low
H - high
7-2 M4307001
Section 7
Electrical Systems
7.2 Electrical Schematic - Swivel, Joysticks
Legend
1. Ignition Switch 36. Relay, accessories
2. Accessories 37. Circuit breaker, 15 Amp
3. Run 38. Wiper motor
4. Start 39. Washer pump switch
5. Starter relay
6. Starter solenoid 40. Washer pump
7. Starter motor 41. Horn switch
8. Batteries (two) 42. Horn
9. Master disconnect switch 43. Heater fan switch
10. Run relay Off
11. Dome light L - low
12. Recirculation fan H - high
13. Fuel Solenoid 44. Heater fan motor
14. Alternator 45. Pressure differential switch
15. Resistor 46. Indicator light, filter change
16. Tachometer 47. Switch, left rear stabilizer
17. Water temperature gauge 48. Switch, left front stabilizer
18. Water temperature sender 49. Switch, right front stabilizer
19. Engine oil pressure gauge 50. Switch, right rear stabilizer
20. Engine oil pressure sender 51. Right thumb switch, saw
21. Voltmeter 52. Left thumb switch, Delimber knives
22. A/C relay 53. Stabilizer pilot valve (Reference)
23. Circuit breaker, 25 Amp (two) 54. Pilot valve, delimber and top saw (Reference)
24. Dome light 55. Detent valve (Reference)
25. Fan switch 56. Valve actuating solenoid (13)
Off 57. Wire numbers used
L - low BL - Blue
M - medium OR - Orange
H - high RE - Red
26. A/C on/off switch
27. Thermostat CL - Close
28. Binary switch OP - Open
29. Motor (evaporator)
30. Control relay No. 1 UP - Up
31. Condenser motor DN - Down
33. Compressor clutch
34. Relay, lights
35. Wiper switch
P - pulse
L - low
H - high
7-4 M4307001
Section 7
Electrical Systems
7.3 Electrical Schematic - Swivel, Lever Controls
Legend
1. Ignition Switch 33. Compressor clutch
2. Accessories 34. Relay, lights
3. Run 35. Wiper switch
4. Start P - pulse
5. Starter relay L - low
6. Starter solenoid H - high
7. Starter motor 36. Relay, accessories
8. Batteries (two) 37. Circuit breaker, 15 Amp
9. Master disconnect switch 38. Wiper motor
10. Run relay 39. Washer pump switch
11. Dome light
12. Recirculation fan 40. Washer pump
13. Fuel Solenoid 41. Horn switch
14. Alternator 42. Horn
15. Resistor 43. Heater fan switch
16. Tachometer Off
17. Water temperature gauge L - low
18. Water temperature sender H - high
19. Engine oil pressure gauge 44. Heater fan motor
20. Engine oil pressure sender 45. Pressure differential switch
21. Voltmeter 46. Indicator light, filter change
22. A/C relay 47. Switch, left rear stabilizer
23. Circuit breaker, 25 Amp (two) 48. Switch, left front stabilizer
24. Dome light 49. Switch, right front stabilizer
25. Fan switch 50. Switch, right rear stabilizer
Off 51. Pilot valve, delimber and top saw (Reference)
L - low 52. Detent valve (Reference)
M - medium 53. Valve actuating solenoid (five)
H - high 54. Wire numbers used
26. A/C on/off switch
27. Thermostat BL - Blue
28. Binary switch OR - Orange
29. Motor (evaporator) RE - Red
31. Condenser motor CL - Close
32. Control relay No. 2 OP - Open
UP - Up
DN - Down
7-6 M4307001
Section 8
10/1996 Troubleshooting
8. Troubleshooting
8.1 General 8-2

8.2 Engine 8-2
8.3 Electrical System 8-8
8.4 Hydraulic System 8-9
M4308001 8-1
Section 8
Troubleshooting 10/1996
8.1 General Information

This section describes some typical problems that can be experienced in the engine, electrical, or hydraulic systems,
their causes, and some possible corrections. The problems listed are not all the problems which can be encountered,
but primarily those that can easily be diagnosed and repaired. Consult your Timberjack or OEM equipment service
specialists for diagnosis and repair of problems that are not listed in this section. A systematic approach to
troubleshooting is essential and should include the following suggestions:
• Study the problems thoroughly before acting.
• Do the easiest and obvious things first.
• Find and correct the basic cause of the problem.
• After making repairs, operate the equipment under normal conditions to verify that the problem and its cause
has been corrected.
8.2 Engine
Engine Will Not Crank or Cranks Slowly
Master disconnect switch turned off. Turn switch on.
Corroded or lose battery connectors. Clean or tighten battery connectors.
Discharged batteries. Charge or replace batteries.
Starter solenoid or starter motor not working. Tighten electrical wire connections.
Refer to OEM equipment Service Manual or
Consult your OEM service representative.
Starter motor operates but does not crank engine. Refer to OEM equipment Service Manual or
8-2 M4308001
Section 8
8.2 Engine
Engine Hard to Start or Will Not Start (Exhaust Smoke Present)
Improper starting procedure. Review starting procedure.
Cold weather. Use cold weather starting aid.
Air in fuel system. Bleed fuel system.
Fuel supply restricted. Drain or replace fuel/water separator.

Replace fuel filter element.
Intake air system restricted. Clean or replace engine air filter.
Contaminated fuel system. Drain, fill, and bleed fuel system as required.
Engine Cranks But Will Not Start (No Smoke From Exhaust)
Improper starting procedure. Review starting procedure.
Fuel tank empty. Fill fuel tank.
Air in fuel system. Bleed fuel system.
Fuel/water separator or fuel filter restricted by water Drain or replace fuel/water separator.
or other contamination. Replace fuel filter element.
M4308001 8-3
Section 8
8.2 Engine
Engine Starts But Stalls Frequently
Idle speed set too low. Adjust engine idle speed.
Malfunctioning engine shut down device. Refer to OEM equipment Service Manual or
Air in fuel system. Bleed fuel lines.
Fuel filter clogged with wax due to cold weather. Drain fuel/water separator.
Change to fuel suitable for operating conditions.
Fuel system contaminated. Drain fuel/water separator.

Drain contaminants from fuel tank.
Fuel supply restricted. Drain fuel/water separator.

Engine Starts But Lacks Power
Engine overloaded. Reduce load.
Restricted intake air flow. Service air cleaner.
Clogged fuel filter. Replace fuel filter element.
Incorrect fuel type. Change fuel to type and grade suitable for
operating conditions.
8-4 M4308001
Section 8
8.2 Engine
Engine Overheats
Engine is overloaded. Reduce load.
Low coolant level. Add coolant to cooling system.
Radiator fins damaged or obstructed with debris. Clean radiator.
Faulty radiator cap. Replace radiator cap.
Loose, damaged, or missing fan belt. Replace fan belt and ensure that belt tensioner
works as required.
Incorrect engine oil level. Add or drain engine oil as required.
Cooling system passages clogged or dirty. Flush cooling system.
Incorrect grade of fuel. Change fuel to suitable grade.
M4308001 8-5
Section 8
8.2 Engine
Low Oil Pressure
Incorrect engine oil level. Add or drain engine oil as required.
Incorrect oil specification. Change engine oil to correct type and viscosity.
Clogged oil filter. Change engine oil and filter.
Engine oil diluted with fuel or coolant. Refer to OEM equipment Service Manual or
Oil Pressure Too High
Engine oil viscosity too high. Change engine oil to correct type and viscosity.
8-6 M4308001
Section 8
8.3 Electrical System
Complete Electrical System Not Functioning
Master disconnect switch is turned off. Turn master disconnect switch on.
Batteries missing or disconnected. Install or connect batteries.
Batteries discharged. Charge or replace batteries.
Corroded battery connections. Clean and tighten battery connections.
Batteries Not Being Charged
Loose or corroded battery connections. Clean and tighten battery connections.
Sulfated or worn-out batteries. Replace batteries.
Loose or damaged engine fan belt. Replace fan belt and check belt tensioner.
Belt tensioner does not functioning correctly. Refer to OEM equipment Service Manual or
Starter Will Not Crank or Cranks Slowly
Loose or corroded cable connections. Clean and tighten loose connections.
Insufficient Battery Voltage. Batteries not being charged. See problem above.
Charge Batteries.
Replace Batteries.
M4308001 8-7
Section 8
8.3 Electrical System
Accessories
All accessories, lower hydraulic system, and A/C With the ignition switch in Run position, check that
system not working. the circuit to accessories solenoid is energized.
With the ignition switch in Acc. position, check that

the circuit to accessories solenoid is energized.
Replace Faulty ignition switch
Test function of accessories solenoid. Replace

solenoid if it is not functioning correctly.
Dome light, defroster, and windshield wiper and Check and reset 15 amp. circuit breaker.
washer not working.
Horn and heater fan not working. Check and reset 15 amp. circuit breaker.
Dome light not working. Check and, if required, replace light bulb.
Lower Hydraulic System
Total lower hydraulic system inoperative. Check and reset 15 amp. circuit breaker.
A/C System
Total A/C system, including dome light, not working. Check and reset 30 amp. circuit breaker.
A/C system with the exception of dome light not Consult your authorized servicing dealer.
working.
A/C system dome light not working. Check light bulb and replace as necessary
8-8 M4308001
Section 8
8.4.1 Main Hydraulic System

No Motion, or Erratic System Operation
Low hydraulic fluid level. Add hydraulic fluid.
Damaged hydraulic line or loose fittings Check for collapsed or damaged suction line(s),
kinked or damaged pressure line(s) and loose or
faulty hydraulic fittings. Repair as required.
Faulty hydraulic pump Check main relief pressure at main or jib control
valve and measure pump output flow at peak
demand. Replace or repair pump if test is not
satisfactory.
Clogged suction strainer Clean or replace suction strainer
Hydraulic fluid is cold. Warm up hydraulic system.
Unsuitable fluid type and viscosity. Change fluid to appropriate type and viscosity.
Main relief valve setting(s) too low Adjust main and/or jib control valve main reliefs to
correct settings.
Relief valve poppet or seat scored and sticking Replace relief valve
Control valve spool not shifted to full stroke Check spool linkage travel and repair as necessary.
M4308001 8-9
Section 8

Oil Leaks Between Control Valve Sections
Pinched or damaged valve section seal. Replace valve section seals.
Valve bank tie bolts incorrectly torqued. Replace valve section seals and tighten valve bank
tie bolts to correct torque.
Oil Leaks at Either End of Valve Spool
Too high tank return pressure. Correct the high back-pressure condition.
Worn or damaged spool seals. Replace spool seals.
Spring Centered Spools Not Returning To Neutral
Broken centering spring. Replace broken spring.
Misalignment of operating linkage. Check linkage for mechanical binding and correct
problem as required.
Foreign particles contaminating the system Clean the valve and the system as required and
replace the fluid.
Load Drops When Spool is Moved From Neutral
Foreign particles lodged between control valve Disassemble, clean and reassemble valve section.
check valve poppet and seat.
Control valve section check valve poppet is Repair valve section check valve as required.
damaged or not seating.
8 - 10 M4308001
Section 8
Hydraulic Cylinder Drifts (Not Holding Load)
Internal cylinder leakage (across piston). Check cylinder assembly and repair as required.
Port relief valve not holding. Remove, clean or replace the port relief.
Control valve spool or housing is scored or Replace the valve section.

excessively worn.
Hydraulic Cylinder Leaks at Rod Bearing
O-ring seal, between rod bearing and cylinder barrel Replace cylinder rod bearing O-ring seal and
is worn, damaged, or incorrectly seated. backup ring.
Hydraulic Fluid Temperature Too High
Dirty or faulty hydraulic cooler. Clean hydraulic cooler.

Replace hydraulic cooler if damaged.
Unsuitable fluid type or viscosity. Change fluid to suitable type and viscosity.
High pressure in tank return circuit. Replace hydraulic filters.

Check tank return lines and fittings and replace
damaged components.
System operated above approved relief pressure. Check main relief pressures. Adjust both main
relief valves to recommended pressures.
Air leak in suction line. Check ball valve and tank connections for tightness.
Repair loose or faulty connections as necessary.
M4308001 8 - 11
Section 8

Hydraulic Fluid Foams
Water in fluid. Change hydraulic fluid and filter.
Hydraulic System Is Noisy
Air leak in the system. Check and add hydraulic fluid as required.
System component hardware loose. Tighten loose hardware.
8.4.2 Lower Hydraulic System

Lower System Does Not Work
Mechanical pump drive shaft broken. Repair or replace mechanical pump drive shaft.
Low fluid level in lower hydraulic tank. Add fluid to lower hydraulic tank.
Hydraulic Cylinders Operate Slowly
Hydraulic fluid is cold. Warm up lower hydraulic system.
Unsuitable fluid type/viscosity. Change fluid to suitable type/viscosity.
8 - 12 M4308001
Section 8
8.4.2 Lower Hydraulic System

Hydraulic Fluid Temperature Too High
Unsuitable fluid type/viscosity. Change fluid to suitable type/viscosity.
High pressure in return circuit - Clogged filter. Replace hydraulic return filter.
Hydraulic Fluid Foams
Water in fluid. Change hydraulic fluid and filter.
Hydraulic System Is Noisy
Air leak in the system. Check and add hydraulic fluid as required.
System component hardware loose. Tighten loose hardware.
M4308001 8 - 13
Section 8
8 - 14 M4308001
Section 9
10/1996 Maintenance and Repair
9. Maintenance and Repair
Group 10. Power Unit and Auxiliary Systems 9 - 10 - 1

Group 20. Hydraulic Systems 9 - 20 - 1
M4309001 9-0-1
Section 9 Group 10
10/1996 Power Unit and Auxiliary Systems
Group 10 - Power Unit and Auxiliary Systems
Component
Number Title . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page No.
1033 10.1 Engine Rubber Mounts . . . . . . . . . . . . . . . . . . . . 9 - 10 - 2

1033 10.2 Engine Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 4
1033 10.3 Pump Adaptor and Drive Plate . . . . . . . . . . . . . . . . . 9 - 10 - 6
1033 10.4 Engine Removal/Installation . . . . . . . . . . . . . . . . . . 9 - 10 - 7
1231 10.5 Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 10

1231 10.6 Swing Gearbox Repair . . . . . . . . . . . . . . . . . . . . 9 - 10 - 12
1231 10.7 Swing Gearbox Special Tools . . . . . . . . . . . . . . . . 9 - 10 - 29
1410 10.8 Air Intake System . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 32
1610 10.9 Hydraulic Fluid Cooler . . . . . . . . . . . . . . . . . . . . 9 - 10 - 35

1610 10.10 Engine Cooling System . . . . . . . . . . . . . . . . . . . 9 - 10 - 36
1830 10.11 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 39
1900 10.12 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 - 41
M43091TC 9 - 10 - 1
Section 9 Group 10
10.1 Engine Rubber Mounts

Cummins Engine
1. Hex Head Bolt 8. Hex Head Bolt

2. Flat Washer 9. Flat Washer
3. Front Engine Bracket 10. Rear Engine Bracket
4. 3-Pc. Engine Rubber Mount 11. 1-Pc. Engine Rubber Mount
5. Front Frame Bracket 12. Rear Frame Bracket
6. Flat Washer 13. Large Flat Washer
7. Hex Lock Nut 14. Hex Lock Nut
John Deere Engine
Component Number 1033

M4309101 9 - 10 - 2
Group 10 Section 9
Power Unit and Auxiliary Systems 10/1996
10.1 Engine Rubber Mounts
10.1.1 General Information 10.1.3 Installation

The engine rubber mounts consist of rubber isolators Important!
placed between the engine mounting brackets and the It is recommended that the rubber mounts are replaced
frame mounting brackets to isolate the loader in pairs, front or rear.
superstructure from engine vibrations.
Clean and inspect the engine and frame mounting
brackets for damage. Repair or replace the brackets as
necessary.
Inspect the rubber mount attaching hardware. Bolts,

washers, and lock nuts that are corroded or damaged
must be replaced to ensure that the mounts can be
secured with the correct torque.
Install new rubber mounts and attaching hardware.
Tighten the rubber mount attaching bolts and lock nuts

as follows:
10.1.2 Removal
Front Mounts: 90 to 100 lb ft (120 to 135 Nm).
Note! Rear Mounts: 175 to 190 lb ft (235 to 255 Nm).
All four engine mounts can be replaced from underneath
the loader. If any of the engine mounting brackets are replaced, the
bracket mounting bolts must be torqued as follows:
Use a high-boy jack to support the front or rear of the
engine as applicable. Cummins Engine
All brackets (3 and 10): 75 to 85 lb ft (100 to 115 Nm).
Remove the lock nuts, washers, and bolts attaching the
rubber mounts. John Deere Engine
Front brackets (3): 175 to 190 lb ft (235 to 255 Nm).
Remove and discard the rubber mounts. Rear brackets (10): 90 to 100 lb ft (120 to 135 Nm).

9 - 10 - 3 M4309101
Section 9 Group 10
10.2 Engine Fan
Cummins Engine
1. Fan Guard 3. Flat Washer

2. Hex Head Bolt 4. Engine Fan
5. Fan Hub
John Deere Engine

M4309101 9 - 10 - 4
Group 10 Section 9
10.2 Engine Fan
10.2.1 General Information 10.2.3 Installation

The engine fan, although not included in the engine Important!
assembly, is part of the complete power unit. Do not attempt to repair a damaged fan. The fan should
always be replaced if it is damaged.
The fan is a suction fan attached to and driven by the
engine. It is located inside the radiator fan shroud with a Clean and inspect the fan, fan hub, and hardware.
protective guard installed behind it to prevent accidental Replace any damaged or heavily corroded components.
contact by personnel.
Install the fan hub and fan using four bolts and flat
washers.
Torque the fan bolts as follows:
Cummins Engine: 24 to 26 lb ft (33 to 35 Nm).

10.2.2 Removal John Deere Engine: 34 to 40 lb ft (46 to 54 Nm).
Remove the fan guard (1). Install the hydraulic fluid cooler, engine radiator, and
radiator fan shroud, refer to Paragraphs 10.9 and 10.10.
Remove the hydraulic fluid cooler, engine radiator and
radiator fan shroud, refer to Paragraphs 10.9 and 10.10. Check and ensure that there is no interference between
the fan blades and the shroud.
Remove the four bolts (2) and washers (3) attaching the
the fan (4) and fan hub (5) to the engine. Install the fan guard.

9 - 10 - 5 M4309101
Section 9 Group 10
10.3 Pump Adapter and Drive Plate
10.3.2 Removal
Remove the triple section hydraulic pump, refer to
Group 20.
Remove the twelve hex head bolts (1) securing the

pump adapter (2) to the engine flywheel housing.
Remove the pump adapter and gasket (3) from the

engine flywheel housing.
Remove the eight hex head bolts (4) and special

washers (5) securing the drive plate (6) to the engine
flywheel.
Remove the retaining ring (7) and remove the splined

bushing (8) from the hub of the drive plate.
10.3.3 Installation
Cummins Engine / John Deere Engine
Clean and inspect all removed components thoroughly.
1. Hex Head Bolt Replace any components that are damaged.
2. Pump Adapter
3. Gasket Insert the splined bushing (8) into the hub of drive
4. Hex Head Bolt plate (6) and install the retaining ring (7).
5. Special Washer
6. Drive Plate Apply LoctiteTM 242 or equivalent to the threads of the
7. Retaining ring eight hex head bolts (4).
8. Splined Bushing
Install the drive plate (6) onto the engine flywheel using
the eight hex head bolts (4) and special washers (5).
Torque the bolts to 34 to 40 lb ft (46 to 54 Nm).
10.3.1 General Information
Install the pump adapter (2) and gasket (3) onto the
The pump adapter and drive plate are the interface engine flywheel housing using the twelve hex head
components used to transfer engine power to the triple bolts (1). Torque the bolts as follows:
section hydraulic pump.
Cummins Engine: 42 to 48 lb ft (57 to 65 Nm).
The drive plate is bolted onto the engine flywheel and
the pump adapter is bolted onto the engine flywheel John Deere Engine: 34 to 40 lb ft (46 to 54 Nm).
housing. The triple section hydraulic pump is secured to
the adapter and connected through a splined coupling to Install the triple section hydraulic pump, refer to
the drive plate. Group 20.

M4309101 9 - 10 - 6
Group 10 Section 9
10.4 Engine Removal/Installation
10.4.1 Removal
Remove the access panels from both sides of the
engine shroud.
Drain the engine and radiator of coolant.
Loosen the exhaust pipe connections between the

turbocharger and the muffler and remove the muffler,
refer to Paragraph 10.11.
On machines with Cummins engine, loosen the

clamp (1) securing the air intake elbow (2) to the air
intake pipe (3).
On machines with John Deere engine, loosen the

clamp (4) and remove the hood (5).
Discharge the A/C system, refer to Group 70.
Disconnect the high pressure and low pressure hoses

from the A/C compressor and pull the hoses clear of the
engine shroud.
Remove the engine shroud, refer to Group 60.
Tag and disconnect the wiring harnesses, wires and

cables at their respective engine connections.
Wrap the harnesses and loose wires and tuck them out
of the way such that they will not interfere with the
removal of the engine.

9 - 10 - 7 M4309101
Section 9 Group 10
Remove the six bolts and flat washers attaching the

hydraulic fluid cooler to the radiator support brackets.
Wrap a protective blanket around the hydraulic fluid

cooler and secure it to the power unit frame away from
the radiator.
Remove the fan guard, radiator, radiator supports, and

fan shroud, refer to Paragraph 10.10.
Remove the throttle cable linkage from the engine fuel

pump and secure the cable out of the way.
CAUTION
Observe strict cleanliness when disconnecting and
connecting hydraulic components. Contamination
induced into the hydraulic system can result in
equipment failure.
Remove the triple section hydraulic pump, refer to

Group 20.
10.4.1 Removal
Disconnect the pilot pump inlet and outlet hoses at the
Disconnect the two cab heater hoses from the engine pilot pump. Refer to Group 20.
connections and tuck the hoses out of the way.
Attach an engine lifting sling to the engine and an
Remove the fuel supply and return hoses from the overhead hoist and take up any slack in the sling.
engine fuel lift pump and return tube, refer to
Paragraph 10.12. Remove the center bolts from the engine mounts, refer
to Paragraph 10.1.
Note!
The hydraulic fluid cooler can remain connected in the Remove the engine from the loader and place it on an
hydraulic system provided it is protected and secured appropriate engine stand.
out of the way so that it does not interfere with the
engine removal.

M4309101 9 - 10 - 8
Group 10 Section 9
Install the fuel supply and return hoses onto the engine
10.4.2 Installation return tube and fuel lift pump, refer to Paragraph 10.12.
Ensure that all auxiliary components removed with or Attach the two cab heater hoses to their respective
from the engine are attached or reinstalled as when the engine inlet and outlet fittings.
engine was removed.
Install electrical cables, harness wires and connectors
Attach an engine lifting sling to the engine and an onto engine connections as tagged.
overhead hoist and take up slack in the sling.
Install the engine shroud, refer to Group 60.
Lift the engine into position in the turntable frame and
install the engine rubber mounts and center bolts, refer Route the A/C hoses through the opening in the engine
to Paragraph 10.1. shroud and install the hoses to the compressor, refer to
Group 60.
Install the engine radiator supports, radiator and fan
shroud, refer to Paragraph 10.10. On Cummins equipped machines, install the air filter
elbow to the air filter housing and engine air intake pipe.
Using new rubber mounting kits, secure the hydraulic
fluid cooler to the radiator supports. On machines with John Deere engine, install the air
intake pipe hood.
CAUTION Install the exhaust muffler, refer to Paragraph 10.11.

connecting hydraulic components. Contamination Fill the engine cooling system with fresh coolant. Refer
induced into the hydraulic system can result in to Section 4 for appropriate coolant and quantity.
equipment failure.
Check the engine oil and add oil as required, refer to
Install the inlet and outlet hoses onto the pilot pump, Section 4 for appropriate oil type and viscosity.
refer to Group 20.
Charge the A/C system, refer to Group 70.
Install the triple section hydraulic pump, refer to
Group 20. Bleed the fuel lines, start the engine, and adjust the
throttle linkage as required.
Install the throttle cable linkage on the engine, refer to
Group 80. Install the access panels on both sides of the engine
shroud.

9 - 10 - 9 M4309101
Section 9 Group 10
10.5 Swing Gearbox

The swing gearbox is a planetary reduction gearbox with
fixed reduction ratio . It is used to provide rotational drive
of the loader superstructure at low speed and high
torque.
The swing gearbox is bolted onto the loader

superstructure such that its large helical pinion gear is in
mesh with the ring gear mounted on the loader base
frame.
1. Hose clamp
2. Hose
3. Barbed Fitting 10.5.2 Removal
4. Swing Gearbox
5. Hex Head Bolt 1. Remove the hydraulic motor from the swing
6. Flat Washer gearbox, refer to Group 20.
7. Countersunk Screw
8. Retainer 2. Remove the hose clamp (1) and hose (2) from the
9. Pinion Gear barbed fitting (3).
3. Drain the oil from the swing gearbox (4).
4. Mark the assembly position of turntable and swing

gearbox.
CAUTION
The swing gearbox is heavy: use appropriate
slings and lifting device to prevent personal
injuries or equipment damage when moving the
gearbox.
5. Remove the 9 bolts (5) and flat washers (6) securing

the swing gearbox to the turntable and remove the
gearbox.

M4309105 9 - 10 - 10
Group 10 Section 9
10.5 Swing Gearbox
10.5.2 Removal
6. Place the swing gearbox on a suitable work bench,
remove the hose fitting (3), and drain the remaining
oil.
7. Remove the two screws (7) that secure the

retainer (8) to the end of the gearbox output shaft
and remove the pinion gear (9).
10.5.3 Installation
1. Install the barbed fitting (3) in the cover of the
gearbox (4).
2. Place the pinion gear (9) on the output shaft such 5. Install the 10 bolts (5) and new flat washers (6) to
that the counterbore in the gear is toward the secure the swing gearbox. Torque the bolts in a
gearbox. crisscross pattern to 320 to 360 lb ft (435 to 490 Nm).
3. Apply LoctiteTM 242 or equivalent to the threads of 6. Install the hose (2) on the barbed fitting (3) and
the two screws (7) and install the two screws to secure with the clamp (6).
secure the retainer (8) to the end of the gearbox
output shaft. Torque the screws to 90 to 100 lb ft 7. Install the hydraulic motor onto the swing gearbox,
(122 to 136 Nm). refer to Group 20 in this section.
4. Position the swing gearbox on the turntable, 8. Fill the swing gearbox with fresh oil. Refer to
ensuring that the assembly marks align. Section 4 for oil specifications.

9 - 10 - 11 M4309105
Section 9 Group 10
10.6 Swing Gearbox Repair

10.6.1 Swing Gearbox Components

M4309106 9 - 10 - 12
Group 10 Section 9
10.6.1 Swing Gearbox Components
1. Hex Head Bolt 23. O-ring Gasket

2. Plug 24. Carrier Housing - Second Stage
3. Cover 25. Planet Pin
4. O-ring Gasket 26. Thrust Washers
5. Thrust Washer 27. Needle Rollers
6. Input Gear 28. Spacer
7. Thrust Washer 29. Planet Gear
8. Thrust Washer 30. Dowel Pin
9. Thrust Bearing 31. Retaining Ring
10. Thrust Washer 32. Lock Nut
11. Carrier Housing - First Stage 33. Keyed Washer
12. Planet Pin 34. Lock washer
13. Thrust Washers 35. Bearing Cone
14. Needle Rollers 36. Bearing Race
15. Planet Gear - First Stage 37. Hub
16. Dowel Pin 38. Bearing Race
17. Thrust Bearing Carrier 39. Bearing Cone
18. Thrust Washer 40. Main Seal
19. Thrust Bearing 41. Output Shaft
20. Thrust Washer 42. Plug
21. Sun Gear 43. Plug
22. Ring Gear 44. Plug
10.6.2 Hub Disassem bly
1. Remove the 24 bolts (1) that secure the cover (2)

and ring gear (3) to the hub (4).
2. Using a marker, mark the assembly position of the

cover (2), ring gear (3), and hub (4).

9 - 10 - 13 M4309106
Section 9 Group 10
10.6.2 Hub Disassem bly
3. Lift the cover (2) off the ring gear (3). Remove and
discard the O-ring gasket (5)
4. Remove the thrust washer (6) from the center hole

counterbore in the cover (2).
5. Remove the large thrust washer (7), thrust

bearing (8), and large thrust washer (9).
6. Remove the input gear (10) from the first stage

carrier assembly (11).

M4309106 9 - 10 - 14
Group 10 Section 9
10.6.2 Hub Disassembly
7. Remove the first stage carrier assembly (11) from

the ring gear (3).
8. Remove the small thrust washer (12) from the top of

second stage sun gear (13).
9. Remove the thrust bearing carrier (14), thrust

washer (15), thrust bearing (16), and thrust
washer (17) from the second stage carrier
assembly (18).
10. Remove the second stage sun gear (13) from the
second stage carrier assembly (18).

9 - 10 - 15 M4309106
Section 9 Group 10
11. Remove the ring gear (3) and O-ring gasket (19)
from the hub (4). Discard the O-ring gasket.
12. Lift the second stage carrier assembly (18) off the
output shaft (20) and remove it from the hub (4).
CAUTION
Use safety glasses when removing the retaining
ring and when using hammer and chisel. Avoid
potential eye injury.
13. Remove the retaining ring (21) from the output

shaft (20).

M4309106 9 - 10 - 16
Group 10 Section 9

14. Using a hammer and chisel, straighten out the tang
on lock washer (22) that secures the lock nut (23).
Note:
The hub and output shaft should be secured in a vise
with protective jaw caps such that the output shaft can
not turn when force to loosen the lock nut is applied.
15. Using fabricated lock nut spanner, refer to

Paragraph 10.7 for tool details, remove the lock nut
(23) from the output shaft (20).
16. Remove the tanged lock washer (22) and keyed

washer (24) from the output shaft (20).
17. Place the hub (4) on support such that the output
shaft (20) can fall clear of the hub. Press the output
shaft out of the bearing cone (25) and remove the
bearing cone from the hub.
18. Remove the bearing cone (26) and main seal (27)
from the output shaft (20). Discard the main seal.

9 - 10 - 17 M4309106
Section 9 Group 10
Important:
To prevent damage to the counterbores take special
care when removing the bearing races from the hub .
19. Using a brass drift punch and hammer, remove the

bearing races (28 and 29) from the hub (4).
20. Remove the four pipe plugs (30, 31, and 32).

M4309106 9 - 10 - 18
Group 10 Section 9
10.6.3 First Stage Planetary Carrier

Disassembly
1. Using a hammer and a drive pin punch, drive the

dowel pin (33) into the planet pin (34) until it bottoms
out against the carrier housing (35).
2. Tap the planet pin (34) out of the carrier

housing (35) and remove the planet gear (36) and
the four thrust washers (37).
3. Remove the needle rollers (38) from the planet

gear (36).

dowel pin (33) out of the planet pin (34).
5. Repeat steps 1 through 4 to disassemble the

remaining two planet gears.

9 - 10 - 19 M4309106
Section 9 Group 10
10.6.4 First Stage Planetary Carrier

Assembly
1. Apply grease to the bore of one planet gear (36) and

line the bore with 19 needle rollers (38).
2. Insert the planet pin (34) into the bore in first stage
carrier housing (35) such that the planet pin just
protrudes the first wall. Ensure that the planet pin
dowel pin hole align with the dowel pin hole in the
carrier housing.
Note:
Grease or petroleum jelly may be used to hold the thrust
washers in place inside the carrier housing.
3. Place two thrust washers (37) on the end of the

planet pin, ensuring that the planet pin does not
protrude beyond the second thrust washer.
4. Place the planet gear (36) and remaining two thrust

washers (37) in the planet carrier and carefully tap
the planet pin into place in the second wall of the
carrier housing.
5. Install the dowel pin (33) into the carrier housing (35)
and planet pin (34), ensuring that the dowel pin is
set approximately 0.1 in. (2.5 mm) below the surface
of the carrier housing.
6. Repeat steps 1 through 5 to install remaining two

planet gears.

M4309106 9 - 10 - 20
Group 10 Section 9
10.6.5 Second Stage Planetary

Carrier Disassembly
1. Using a hammer and drive pin punch, drive the

dowel pin (39) into the planet pin (40) until it bottoms
out against the carrier housing (41).
2. Tap the planet pin (40) out of the carrier

housing (41) and remove the planet gear (42) and
four thrust washers (43).
3. Remove the two rows of needle rollers (44) and

spacer (45) from the bore of planet gear (42).

dowel pin (39) out of the planet pin (40).
5. Repeat steps 1 through 4 to disassemble the

remaining two planet gears.

9 - 10 - 21 M4309106
Section 9 Group 10
10.6.6 Second Stage Planetary

Carrier Assembly
1. Apply grease to the bore of one planet gear (42) and

line the bore with one row of 18 needle rollers (44).
2. Install the spacer (45) and line the bore with the
second row of needle rollers.
3. Insert the planet pin (40) into the bore in the carrier
housing (41) so that the planet pin just protrudes the
first wall. Ensure that the planet pin dowel pin hole
align with the dowel pin hole in the carrier housing.
Note:
Grease or petroleum jelly may be used to hold the thrust
washers in place inside the carrier housing.
4. Place two thrust washers (43) on the end of the

planet pin (40). Ensure that the planet pin does not
protrude beyond the second thrust washer.
5. Place the planet gear (42) and remaining two thrust

washers (43) in the planet carrier (41) and carefully
tap the planet pin (40) into place in the second wall
of the carrier housing.
6. Install the dowel pin (39) into the carrier housing and
planet pin, ensuring that the dowel pin is set
approximately 0.1 in. (2.5 mm) below the surface of
the carrier housing.
7. Repeat steps 1 through 6 to install the remaining two

planet gears.

M4309106 9 - 10 - 22
Group 10 Section 9
10.6.7 Hub Assembly
Note:
The magnetic pipe plug should be installed in the
location most accessible when the swing gearbox is
installed on the loader.
1. Apply a light coat of Never-seize compound to the

four pipe plugs (30, 31, and 32) and install the plugs in
the hub (4).
Important:
To prevent damage to the hub, ensure that the bearing
races are properly aligned with their respective bores
before they are pressed into place.
2. Using an arbor press and manufactured installation

tool, refer to Paragraph 10.7 for tool details, install
the bearing race (29) into the hub (4).
3. Using an arbor press and manufactured installation

the bearing race (28) in the hub (4).
4. Apply oil to the bore of bearing cone (26) and, using

an arbor press and manufactured installation tool,
refer to Paragraph 10.7 for tool details, install the
bearing cone on the output shaft (20).

9 - 10 - 23 M4309106
Section 9 Group 10
10.6.7 Hub Assembly
5. Place the hub (4) over the output shaft (20).
6. Apply oil to the bore of the bearing cone (25) and,

using an arbor press and manufactured installation
the bearing cone on the output shaft (20).
7. Reduce and then reapply press pressure on the

bearing cone while turning the hub alternately in
clockwise and counterclockwise directions. Stop
press action when resistance to turning is felt.
8. Install and tighten firmly one cover bolt (1) in the

hub (4).
9. Using a socket and torque wrench, place the torque

wrench on the bolt (1) so that the axis of the torque
wrench is tangential to the circumference of the hub.
10. Turn the hub (4) one full rotation on the output
shaft (20) and observe the indicated torque value.
11. Repeat the rolling torque measurement several

times to ensure that an accurate reading is obtained.
The initial rolling torque should be 25 to 30 lb in.
(2.8 to 3.4 Nm)
12. If the bearing preload is too high, strike the top of the
output shaft with a dead blow hammer and repeat
steps 9 through 11.

M4309106 9 - 10 - 24
Group 10 Section 9
10.6.7 Hub Assembly
13. Install the keyed washer (24) and tanged lock

washer (22) on the output shaft (20).
Note:
Loctite 277 will cure when no longer in contact with air.
Therefore, torque the lock nut immediately when
installed.
14. Prime the threads on output shaft (20) and

lock nut (23) with Locquic Primer T and allow to dry
for at least two minutes.
Important:
Once torqued, the lock nut must not be loosened to align
lock washer and lock nut. If necessary, the lock nut must
be tightened extra to achieve alignment.
15. Install the lock nut (23) on the output shaft (20) and,
using manufactured lock nut spanner, refer to
Paragraph 10.7 for tool details, and a torque wrench,
torque the lock nut to 225 lb ft (305 Nm).
16. Measure the final rolling torque of the hub on the

output shaft as detailed in steps 9 through 11. The
final rolling torque should be 35 to 60 lb in.
(4.0 to 6.8 Nm).
17. Bend one tang on the lock washer (22) into a notch
in the lock nut (23) to secure the lock nut.
18. Using a center punch and hammer, stake the

lock nut (23) in four equally spaced places
approximately 1/8 in. (6 mm) out from the edge of
the thread.
19. Remove the bolt (1) from the hub (4).
20. Apply oil to the seal area of the output shaft (20) and
the hub (4) and, using manufactured tool, refer to
Paragraph 10.7 for tool details, and an arbor press,
install a new seal (27).

9 - 10 - 25 M4309106
Section 9 Group 10
10.6.7 Hub Assembly
CAUTION
Avoid potential eye injury: use safety glasses when
installing retaining ring.
21. Using retaining ring pliers, install the retaining

ring (21) in the groove on output shaft (20).
22. Insert the second stage carrier assembly (18) in the

hub (4) such that the splines in the carrier housing
mesh with the splines on the output shaft (20).
23. Apply oil to exposed surfaces of the second stage

carrier assembly (18) and the inside of hub (4).
24. Wipe the counterbore in the hub (4) with a clean dry
cloth to ensure that it is free of oil.
Note:
If too small, the O-ring gasket can be stretched to fit the
counterbore. If stretched too much, the gasket may be
squeezed smaller bit-by-bit as it is placed in the
counterbore.
25. Apply grease to the O-ring gasket (19) and place the
gasket in the counterbore on hub (4).
26. Apply oil to the teeth of the ring gear (3) and install
the ring gear on the hub (4), ensuring that the ring
gear mesh with the planet gears in the second stage
carrier (18) and the assembly marks on the ring gear
and hub align.

M4309106 9 - 10 - 26
Group 10 Section 9
10.6.7 Hub Assembly
27. Install the second stage sun gear (13) with the large
diameter of the gear in mesh with the planet gears in
the second stage carrier (18).
28. Place the large thrust washer (17), thrust

bearing (16), and large thrust washer (15) into the
counterbore in the second stage carrier (18).
29. Install the thrust bearing carrier (14) with the

recessed side against the thrust washer (15).
30. Install the first stage carrier assembly (11) so that

the splined bore of the carrier housing mesh with the
second stage sun gear (13) and the planet gears
mesh with the ring gear (3).
31. Place the small thrust washer (12) on top of the

second stage sun gear (13).
32. Place the cover (2) upside down and apply grease to
one side of the large thrust washer (7), thrust
bearing (8), and thrust washer (9). Place the items
with the greased side down over the raised inside
edge of the cover (2).
33. Apply grease to the small thrust washer (6) and

install it into the counterbore of the center hole in the
cover (2).
34. Apply grease to the O-ring gasket (5) and place it in

the counterbore on the cover (2).

9 - 10 - 27 M4309106
Section 9 Group 10
10.6.7 Hub Assembly

35. Insert the input gear (10) with the male splined end
11
into mesh with the planet gears of the first stage
carrier assembly (11), ensuring that the end of the
input gear fits into the thrust washer on top of the
second stage sun gear.
36. Install the cover (2) on the ring gear (3), ensuring
that the assembly marks on the outside surface of
the cover and the ring gear align. Ensure that the
thrust bearing and thrust washers, installed
previously, remain in place on the cover during
installation.
37. Install the 24 bolts (1) to secure the cover (2) and
the ring gear (3) on the hub (4).
38. Torque the bolts in a crisscross pattern to

35 to 45 lb ft (47 to 61 Nm).

M4309106 9 - 10 - 28
Group 10 Section 9
10.7 Swing Gearbox Special Tools
The following specialized tools are used in disassembly

and assembly of the swing gearbox. The tool diagrams
are intended for the user who may wish to have the tools
made. All the tools should be manufactured from mild
steel. Tool dimensions are provided in inches.
To improve tool life the tools can be case hardened.

However, if this is done, all surfaces labeled "G" must be
ground.
Note:
The tool diagrams are not to scale.
T-156766 - An-18 Lock Nut Wrench
Note:
The 3/4 in. drive socket is not shown.
* Typical. 4 lugs equally spaced

** Tap two holes 3/4 in. deep 180o apart.
*** Loose fit for 3/4 in. drive socket to be welded in
place.
T-156792 - Bearing Cup Pressing Fixture
* Press fit.

9 - 10 - 29 M4309106
Section 9 Group 10
T-158049 - Bearing Cone Pressing Fixture
* Knurl handle
T-146588 - Bearing Cone Pressing Fixture

M4309106 9 - 10 - 30
Group 10 Section 9
T-130717 - Bearing Cup Pressing Fixture
T-156799 - Seal Pressing Fixture
* Drill 1/4 in. diameter hole through the body of the

tool as shown.
** Press fit.

9 - 10 - 31 M4309106
Section 9 Group 10
10.8 Air Intake System
removed before the air is forced by the turbocharger into

10.8.1 General Information the engine.
The air intake system consists of the air filter housing, Depending on the type of air filtration required by the
air filter(s), and air intake piping between the air filter particular engine, the air filter housing may contain one
housing and the engine turbocharger. or two filter elements. When two elements are used, the
second or secondary element is generally considered a
Combustion air supply is drawn through the air filter(s) safety filter that will maintain the air filtration should the
where all heavy and damaging dust particles are first or primary filter become damaged.
10.8.2 Removal/Installation - Cummins Engine

Air Intake System - Cummins Engine
1. Hood 11. Clamp

2. Clamp 12. Filter Housing
3. Dust Cup 13. Housing Band
4. Vacuator Valve 14. Bolt
5. Wing Nut and Sealing Ring 15. Flat Washer
6. Air Filter Element 16. Hex Nut
7. Housing Clamp 17. Pipe
8. Filter Condition Indicator 18. Clamp
9. Clamp 19. Elbow
10. Elbow 20. Clamp

M4309108 9 - 10 - 32
Group 10 Section 9
10.8.2 Removal/Installation - Cummins Engine

Items (1 through 10) are accessible from outside the free so that unfiltered air is prevented from entering the
engine shroud. engine.
To remove and install items (11 through 19), the front There are no specific torque values for any of the
engine access panel needs to be removed. fastening hardware.
If replacing any of the components (9, 11, 16, or 18),

ensure that the joints are left securely tightened and leak

9 - 10 - 33 M4309108
Section 9 Group 10
10.8.3 Removal/Installation - John Deere Engine

Air Intake System - John Deere Engine
1. Hood 10. Clamp

2. Clamp 11. Preformed Hose
3. Pipe 12. Filter Housing
4. Clamp 13. Housing Clamp
5. Housing Band 14. Dust Cup
6. Hex Head Bolt 15. Baffle
7. Flat Washer 16. Wing Nut
8. Hex Nut 17. Primary Air Filter Element
9. Clamp 18. Wing Nut
19. Secondary Air Filter Element
Only items (1 and 2) are accessible from outside the When replacing the preformed hose (11), ensure that
engine shroud. the hose joints are left securely tightened and leak free
to prevent unfiltered air from entering the engine.
To remove and install items (3 through 19), the front
engine access panel needs to be removed. There are no specific torque values for any of the
fastening hardware.

M4309108 9 - 10 - 34
Section 9 Group 10
10.9 Hydraulic Fluid Cooler

The hydraulic fluid cooler, although an integral
component in the hydraulic system, is for the purpose of
service and spare parts covered in the same component
number group as the engine radiator due to its location
and shared means of heat exchange.
10.9.2 Removal/Installation
Remove the engine shroud grille plate to access the
upper hydraulic fluid cooler bolts.
CAUTION!
equipment failure.
1. Hydraulic Return Hose
2. Hydraulic Tank Hose
Important! 3. Hex Head Bolt
When installing a new or rebuilt fluid cooler, 4. Flat Washer
ensure that the hydraulic flow follows the direction 5. Rubber Block
indicated on the fluid cooler. 6. Hydraulic Fluid Cooler
To prevent contamination and minimize fluid spill, cap The hydraulic fluid cooler mounting hardware should be
the hydraulic hoses and fluid cooler connections replaced when the rubber blocks show signs of
immediately after disconnecting the hoses. deterioration or a new or repaired fluid cooler is installed.

M4309109 9 - 10 - 35
Group 10 Section 9
10.10 Engine Cooling System

The engine cooling system consists of the radiator, The radiator is of the tube and fin type; however, the
radiator support, fan shroud, fan guard, and the coolant number of tubes and cooling fins vary with the
hoses between the radiator and engine. application.
Combustion heat developed in the engine is transferred Apart from other minor physical differences, the
by the engine coolant to the radiator where the heat is Cummins Engine cooling System operates at pressures
dissipated to the ambient environment by air flow up to 14 psi (97 kPa), whereas the John Deere cooling
passing through the radiator core. system operates at pressures below 7 psi (48.5 kPa).
Cooling System - Cummins Engine
1. Radiator Support Bracket (right) 12. Hex Nut

2. Bolt 13. Bolt
3. Flat Washer 14. Flat Washer
4. Bolt 15. Radiator Support Bracket (left)
5. Flat Washer 16. Radiator
6. Hex Nut 17. Radiator Hose
7. Radiator Brace 18. Hose Clamp
8. Fan Guard 19. Radiator Hose
9. Fan Shroud 20. Hose Clamp
10. Bolt 21. Drain Cock
11. Flat Washer 22. Clamp

9 - 10 - 36 M4309109
Section 9 Group 10

Cooling System - John Deere Engine
1. Radiator Support Bracket (right) 11. Flat Washer

2. Radiator Support Bracket (left) 12. Hex Nut
3. Bolt 13. Bolt
4. Flat Washer 14. Radiator Hose
5. Hex Nut 15. Hose Clamp
6. Radiator 16. Radiator Hose
7. Bolt 17. Hose Clamp
8. Flat Washer 18. Drain Cock
9. Radiator Brace 19. Clamp
10. Bolt 20. Fan Guard

M4309109 9 - 10 - 37
Group 10 Section 9
10.10.2 Removal 10.10.3 Installation

Drain the cooling system completely of coolant. Thoroughly flush the engine before installing a new or
repaired radiator.
Remove the hydraulic fluid cooler, refer to
Paragraph 10.9. Pre-assemble the radiator supports, fan shroud, and
radiator on the shop floor.
Remove the bolts attaching the fan guard and remove
the fan guard from the fan shroud. Carefully lift the radiator sub-assembly into place on
the turntable frame cross member, taking care not to
Remove the upper and lower radiator hoses. damage the engine fan.
Remove the bolts attaching the two radiator braces and Install and hand-tighten the bolts to secure the radiator
remove the braces. supports to the turntable cross member.
Remove the bolts attaching the left and right radiator

supports to the turntable frame cross member and
carefully lower the assembled radiator, fan shroud, and
radiator supports out of the turntable frame, taking care
not to damage the engine fan.
Disassemble the radiator supports and fan shroud from

the radiator as required.
Check that the engine fan protrudes out of the fan

shroud 0.75 in. (19 mm) as shown, ensuring that the
shroud is square to the fan.
Tighten and torque the radiator support mounting bolts

to 90 to 100 lb ft (122 to 136 Nm).
Install the two radiator braces to the radiator supports

and engine shroud.
Install the upper and lower radiator hoses.
Install the fan guard onto the fan shroud.
Install the hydraulic fluid cooler, refer to Paragraph 10.9.
Fill the cooling system with a fresh coolant mixture, refer

to Section 4 for coolant specifications.

9 - 10 - 38 M4309109
Section 9 Group 10
10.11 Exhaust System

Cummins Engine
1. Muffler 6. Flat Washer

2. Clamp 7. Locknut
3. Tail Pipe 8. Clamp
4. Spacer Bracket 9. Reducer Pipe
5. Isolator Mount 10. Clamp
John Deere Engine

M4309111 9 - 10 - 39
Group 10 Section 9
10.11 Exhaust System
10.11.1 General Information WARNING!

The exhaust system comprises the pipe components Operate acetylene cutting equipment with caution.
and muffler connected to the exhaust port of the engine Wear appropriate face shield, gloves, and protective
turbocharger. clothing and avoid aiming the cutting torch at any
combustible materials.
The function of the exhaust system is to direct the
engine exhaust gasses away from the engine air intake
and at the same time muffle the noise from the engine If any exhaust system components are corroded or
combustion. damaged, it may be advantageous to flame cut these
items to remove them and then replace them with new
components.
When installing the pipe clamps, tighten the nuts firmly
without damaging the clamps or the pipe components.
WARNING! There are no specific torque values for any of the
Do not touch hot exhaust system components.
fastening hardware.
Allow sufficient time for the components to cool
before initiating any work on the system.
Other than removing the engine shroud access panels in

order to access the turbocharger connection and the
isolator mount locknuts, there are no constraints on
removal and installation of the exhaust system
components.

9 - 10 - 40 M4309111
Section 9 Group 10
10.12 Fuel System

The fuel pump, the fuel filter(s), and the components
The fuel system consists of the fuel tank, the fuel supply that are integrated parts of the engine are not covered in
and return hoses, the fuel/water separator, the shut-off this manual. For information concerning these
ball valve and the various fittings connecting the system components refer to the appropriate engine service
and the engine. manual.
Fuel System - Machines With Cummins Engine
1. Fuel Tank 10. Nipple

2. Tank Vent 11. Adapter
3. Tank Cap 12. Connector
4. Drain Cock 13. Nipple
5. Nipple 14. Nipple
6. Return Hose 15. 90-Deg. Elbow
7. Supply Hose 16. Fuel Hose
8. 45-Deg. Elbow 17. 90-Deg. Elbow
9. Ball Valve 18. Fuel/Water Separator

M4309112 9 - 10 - 41
Group 10 Section 9
10.12 Fuel System

Fuel System - Machines with John Deere Engine
1. Fuel Hose 10. Tank Cap

2. Nipple 11. Tank Vent
3. 90-Deg. Elbow 12. Drain Cock
4. 90-Deg. Elbow 13. Nipple
5. Supply Hose 14. Nipple
6. Return Hose 15. Ball Valve
7. Connector 16. 45-Deg. Elbow
8. Adapter 17. Fuel/Water Separator
9. Fuel Tank
All components in the fuel system are directly accessible

WARNING! from under the turntable frame or from the engine
Do not smoke or use open fire in close proximity of compartment.
the machine when working on the fuel system.
Wear protective clothes, face shield, and gloves as No special tools are required, and there are no specific
necessary when exposed directly to the liquid fuel. torque values for any of the fastening hardware.

9 - 10 - 42 M4309112
Section 9 Group 20
20.1 Triple Section Main Pump

The triple section main pump consists of three integrated
pump sections that are driven by the engine through a
common input shaft.
The triple section pump is used to generate hydraulic

flow for operation of the loader.
1. Triple Section Main Pump

2. Bolt
3. Flat Washer
4. 90-Deg. Elbow
5. O-Ring
6. Flange Mounting Kit
20.1.2 Removal
CAUTION
Attach a DO NOT START warning tag to the ignition
key or a control lever before undertaking work on
the hydraulic system. Attempts to run the engine
while the hydraulic system is disabled can result in
personal injuries and equipment damage.
Important!
Cap all hydraulic ports, hoses, and fittings immediately
after removal to prevent the components from becoming
contaminated. Contamination introduced into the
hydraulic system can lead to premature equipment
failure.
1. Close the two hydraulic tank ball valves (1).
2. Tag the hydraulic inlet and outlet hoses to ensure

correct reassembly.
3. Remove eight bolts (2) and four half flanges (3) that
secure inlet hoses (4 and 5) to pump assembly (6).
4. Remove and discard the inlet hose O-rings and drain

and cap the inlet hoses.

M4309201 9 - 20 - 3
Group 20 Section 9
20.1.2 Removal
5. Remove the three outlet hoses (7, 8, and, 9) from

the elbows on pump assembly (6). Drain and cap
the outlet hoses.
CAUTION
The hydraulic gear pump assembly is heavy! Use
appropriate support, slings, and lifting device to
prevent personal Injuries or equipment damage
when moving the pump assembly.
6. Place appropriate support under the pump

assembly, and remove the four bolts (10) that
secure the pump assembly to pump drive
housing (11).
7. Remove the pump assembly from the loader and

place it on a workbench.
Note!
To ensure correct reassembly, the position of the elbows
should be noted before they are removed.
8. Remove the three elbows (12) and O-rings (13) from

the pump assembly outlet ports.

9 - 20 - 4 M4309201
Section 9 Group 20
21.1.3 Installation
CAUTION
equipment failure.
1. Install new O-rings (13) on all three elbows (12).
2. Install the elbows into the outlet ports in pump

assembly (6), making sure that the elbows are
positioned as noted prior to removal.
3. Inject a small amount of hydraulic fluid into each inlet

and outlet port and cap the ports.
4. Using appropriate lifting device and support, position

pump assembly (6) in assembly position with the
pump drive housing (11).
5. Install the four bolts (10) to secure pump

assembly (6) to the pump drive housing. Torque the
bolts to 90 to 100 lb ft (122 to 136 Nm).

M4309201 9 - 20 - 5
Group 20 Section 9
21.1.3 Installation
Note!
Ensure that all hoses are installed as tagged.
6. Install outlet hoses ( 7, 8, and, 9 ) onto the elbows in

pump assembly (6).
7. Install new O-rings on inlet hoses (4 and 5).
8. Install eight bolts (2) and four half flanges (3) to

secure the inlet hoses to the pump assembly.
Tighten the bolts to 28 lb ft (38 Nm).
9. Open the two tank ball valves (1).

9 - 20 - 6 M4309201
Section 9 Group 20
20.2 Triple Section Main Pump Repair

Dirt or contamination induced into any hydraulic procedures, be manufactured and made available.
component or system is a major cause of premature Manufacturing details for these special tools are shown
failure. Therefore, strict cleanliness should be exercised in Paragraph 20.7.
when the pump is removed or installed on the vehicle
and during repair of the unit on the bench. Whenever a To prevent damage to machined surfaces, be extra
hydraulic line is disconnected or a component is opened careful when using pry bars or securing any part of the
up, ensure that exposed hose ends and ports are hydraulic pump in a vice. Use protective jaw caps
capped immediately. This not only protects against whenever necessary.
contamination but also reduces unwanted hydraulic fluid
spill. When components are disassembled, ensure that The hydraulic pump must be driven in the direction of
they are completely cleaned, air blasted, and wiped with rotation for which it was built; otherwise, pressure will
clean lintless cloth before being assembled. blow the shaft seals.
To minimize the risk of damage to any components as Use identifying markings wherever necessary during
well as reduce the time to perform repair to the pump, it disassembly to ensure that all parts are assembled
is recommended that the special manufactured tools, exactly as disassembled.
mentioned in the disassembly and assembly

M4309202 9 - 20 - 7
Group 20 Section 9
20.2.2 Triple Section Main Pump Components
1. Channel Seal 13. Second Section Gear Housing

2. Thrust Plate 14. Drive Gear - Second Section
3. Gasket Seal 15. Driven Gear - Second Section
4. First Section Gear Housing 16. Connecting Shaft
5. Drive Gear - First Section 17. Bearing Carrier - Second and Third Sections
6. Driven Gear - First Section 18. Port End Cover
7. Shaft End Cover 19. Third Section Gear Housing
8. Bearing 20. Drive Gear - Third Section
9. Double Lip Seal 21. Driven Gear - Third Section
10. Retaining Ring 22. Hex Nut
11. Vibration Dampner O-Ring 23. Flat Washer
12. Bearing Carrier - First and Second Sections 24. Stud

9 - 20 - 8 M4309202
Section 9 Group 20
20.2.2 Triple Section Main Pump Components

M4309202 9 - 20 - 9
Group 20 Section 9
20.2.3 Pump Disassembly

20.2.3.1 Third Pump Section
1. Place the pump on a work bench and match mark all

sections to ensure correct reassembly.
Important!
Do not clamp on any machined surface to hold the pump
components during disassembly.
2. Remove the four hex nuts (1) and flat washers (2)
securing the pump sections together.
Note!
Dowel pins are used between the end covers, gear
housings, and bearing carriers. These dowel pins should
not be removed but left installed in the components they
are secured in.
3. Lift the port end cover (3) off the third section gear
housing (4), being careful not to damage the
machined surfaces.
4. Remove the four studs (5).
Note!
If vibration dampner O-rings are installed on the studs,
these O-rings should be removed and discarded.
5. Remove thrust plate (6) and gasket seal (7) from

third section gear housing (4) and remove channel
seal (8) from the thrust plate. Discard the channel
and gasket seals.

9 - 20 - 10 M4309202
Section 9 Group 20

20.2.3.1 Third Pump Section Cont.
6. Carefully remove the drive gear (9) and driven

gear (10) from the third section gear housing (4).
Avoid tapping the gear teeth together or against
other hardened surfaces. The two gears are a
matched set and should be kept together.
7. Remove thrust plate (11) from the face of bearing

carrier (12) and remove channel seal (13) from the
thrust plate.
8. Lift the third section gear housing (4) from bearing

carrier (12), being careful not to damage the
machined surfaces. Remove gasket seal (14) and
discard.
20.2.3.2 Second Pump Section
9. Carefully remove bearing carrier (12) from the

second section gear housing (15), being careful not
to damage the contact face and edges of the
bearing carrier or the second section gear housing.
10. Remove connecting shaft (16), thrust plate (17), and

gasket seal (18) from the second section gear
housing (15) and remove channel seal (19) from the
thrust plate. Discard the channel and gasket seals.

M4309202 9 - 20 - 11
Group 20 Section 9

20.2.3.2 Second Pump Section Cont.
11. Carefully remove drive gear (20) and driven

gear (21) from the second section gear housing (15).
12. Remove thrust plate (22) from the face of bearing

carrier (23) and remove channel seal (24) from the
thrust plate.
13. Lift the second section gear housing (15) from

bearing carrier (23), being careful not to damage the
discard.
20.2.3.3 First Pump Section
14. Carefully remove bearing carrier (23) from the first

section gear housing (26), being careful not to
damage the contact face and edges of the bearing
carrier or the gear housing.
15. Remove connecting shaft (27), thrust plate (28), and

gasket seal (29) from the first section gear
housing (26) and remove channel seal (30) from the

9 - 20 - 12 M4309202
Section 9 Group 20

20.2.3.3 First Pump Section Cont.

gear (32) from the first section gear housing (26).
17. Remove thrust plate (33) from the face of shaft end
cover (34) and remove channel seal (35) from the
thrust plate. Discard the channel seal.
18. Lift the first section gear housing (26) from shaft end
cover (34), being careful not to damage the
discard.
20.2.3.4 Pump Base
19. Secure shaft end cover (34) in a vise, with the pump
mounting flange facing up, and remove retaining
ring (37).
20. Using a suitable bearing puller, remove bearing (38)

from shaft end cover (34).
21. Using a special manufactured seal removal tool and

ball peen hammer, carefully remove double lip
seal (39) from shaft end cover (34). Discard the seal.

M4309202 9 - 20 - 13
Group 20 Section 9
20.2.4 Pump Assembly

Clean all disassembled parts and inspect applicable
components for wear and damage as detailed in
paragraph 20.5.
20.2.4.1 Pump Base
1. Stone all flat machined surfaces using a medium grit

carborundum stone and rinse the parts in cleaning
solvent. Air blast and, using clean lintless cloth, wipe
all parts clean, before starting assembly.
Important!
One plug is installed in the outlet side of the shaft end
cover and port end cover respectively. These plugs
should not be removed or replaced.
2. Ensure that dowel pins (40) are installed in all

applicable pump sections. Use a soft faced hammer
to install missing dowel pins, ensuring that each
replacement dowel pin is started straight and lightly
tapped in place.
3. Coat mating surfaces of new double lip seal (39) and

the recessed bore in shaft end cover (34) with
Permatex Aviation Form-A-Gasket No. 3
non-hardening sealant or equivalent.
4. With the metal side of the new double lip seal facing
up, and using an arbor press and special
manufactured bar, press the double lip seal into the
recessed bore in the shaft end cover until it seats
flush with the edge of the recess. Wipe off excess
sealant.

9 - 20 - 14 M4309202
Section 9 Group 20

20.2.4.1 Pump Base Cont.
5. Using a soft faced hammer and a brass drift punch,

install bearing (38) into the bore in shaft end
cover (34), ensuring that the bearing seats fully
against the recess at the bottom of the bore.
6. Install retaining ring (37) to secure bearing (38) in

place in the pump base.
20.2.4.2 First Pump Section
7. Apply grease to six new gasket seals and insert the

seals in the grooves on first, second, and third
section gear housings.
8. Install six new channel seals into the thrust plates,

ensuring that the concave side of each channel seal
faces into the groove in the thrust plate.

M4309202 9 - 20 - 15
Group 20 Section 9

9. Position the first section gear housing (26) on shaft

end cover (34), making sure that assembly markings
on the casting exteriors align.
10. Using a soft faced hammer, and making sure that

the gear housing engages properly with the dowel
pins (40), tap lightly on the gear housing until it seats
tightly against the shaft end cover. Be careful not to
pinch the gear housing gasket seal.
11. With the channel seal facing down, insert thrust

plate (33) through the first section gear housing (26)
and place it on shaft end cover (34). Ensure that the
relief groove in the thrust plate faces the outlet side
of the pump.
12. Insert driven gear (32) in the first section gear

housing (26) and into the bore in shaft end
cover (34).

9 - 20 - 16 M4309202
Section 9 Group 20

Important!
If installed without the use of the special manufactured
sleeve tool, the lips of the new double lip seal may be
damaged.
13. Coat special sleeve tool (A), ref. Paragraph 20.7 for
tool details, with grease and place the splined end of
driving gear (31) inside the sleeve.
14. With a twisting motion, insert and push the tool

carefully through the double lip seal in the shaft end
cover (34) until the teeth of the driving gear mesh
with the teeth of driven gear (32). Apply oil to the
teeth of both gears after installation.
15. With the channel seal facing up, install thrust

plate (28) over the journals of gears (31 and 32) and
into the bore of first section gear housing (26).
Ensure that the thrust plate relief groove is facing
the outlet side of the gear housing.
16. Align the journals of gears (31 and 32) with the
bores in bearing carrier (23) and install the bearing
carrier on the first section gear housing. Ensure that
assembly markings on the casting exteriors align.
17. Using a soft faced hammer, tap on the bearing

carrier until it seats tightly against the first section
gear housing.

M4309202 9 - 20 - 17
Group 20 Section 9

18. Install four studs (5), through the assembled pump

sections, into the shaft end cover.
Note!
Vibration dampner O-rings should be installed on the
four pump studs to minimize vibration of the studs when
the pump is operating.
19. Using O-ring installation tool (B), ref. Paragraph 20.7

for tool details, install three O-rings (41) on each of
the four studs (5).
20. Using O-ring insertion tool, ref. Paragraph 20.7 for

tool details, push the O-rings on each stud into the
bearing carrier such that the second O-ring is
located approximately in the middle and the first and
third O-rings approximately 1/8 to 1/4 in. in from the
ends of the bearing carrier.

9 - 20 - 18 M4309202
Section 9 Group 20

20.2.4.3 Second Pump Section
21. Install the connecting shaft (27) through the bore in

the bearing carrier (23) and into the splines in first
section driving gear.
22. Position the second section gear housing (15) on the

bearing carrier (23), making sure that assembly
markings on the casting exteriors align.
23. Using a soft faced hammer, and making sure that

the gear housing engages properly with the dowel
pins (40), tap lightly on the second section gear
housing until it seats tightly against the bearing
carrier. Be careful not to pinch the gear housing
gasket seal.
24. With the channel seal facing down, Insert thrust

plate (22) into place on bearing carrier (23), ensuring
that the relief groove in the thrust plate faces the
outlet side of the pump.
25. Install driven gear (21) in the second section gear

housing (15) and into the bore in bearing carrier (23).
26. Install driving gear (20) onto the splined connecting

shaft in first section driving gear.

M4309202 9 - 20 - 19
Group 20 Section 9

20.2.4.3 Second Pump Section Cont.

plate (17) over the journals of gears (20 and 21).
the outlet side of the gear housing.
28. Install bearing carrier (12) on the second section

gear housing (15), ensuring that the assembly
29. Using a soft faced hammer, tap on the bearing

carrier until it seats tightly against the second
section gear housing.
30. Using O-ring installation tool (B), ref. Paragraph 20.7

for tool details, install three O-rings (41) on each of
the four studs (5).
31. Using O-ring insertion tool, ref. Paragraph 20.7 for

tool details, push the O-rings into the bearing carrier
such that the second O-ring is located approximately
in the middle and the first and third O-rings
approximately 1/8 to 1/4 in. in from the ends of the
bearing carrier.

9 - 20 - 20 M4309202
Section 9 Group 20
20.2.4.4 Third Pump Section
32. Install connecting shaft (16) through the bore in

bearing carrier (12) and into the splines in second
section driving gear.
33. Position the third section gear housing (4) on

bearing carrier (12), making sure that the
dowels (40) are in place and the assembly markings
on the casting exteriors align.
34. Using a soft faced hammer, tap lightly on the third

section gear housing until it seats tightly against the
bearing carrier. Be careful not to pinch the bearing
carrier gasket seal.
11
35. Install thrust plate (11) with the channel seal facing
down, onto the bearing carrier (12), ensuring that the
relief groove in the thrust plate faces the outlet side
of the pump.
36. Install driven gear (10) in third section gear

housing (4) and into the bore in bearing carrier (12).
37. Install the driving gear (9) onto the splined

connecting shaft in the second section driving gear.

M4309202 9 - 20 - 21
Group 20 Section 9

20.2.4.4 Third Pump Section Cont.

plate (6) over the journals of gears (9 and 10).
the outlet side of the third section gear housing (4).
39. Position port end cover (3) on studs (5), ensuring

that the assembly markings on the exterior of the
castings align.
40. Ensure that the dowel pins are in place and, using a
soft faced hammer, tap on the port end cover until it
seats tightly against the third section gear housing.
41. Install four flat washers (2) and lock nuts (1) to
secure the pump sections together.
42. Using an appropriate size 12 point socket and

ratchet handle, rotate the pump drive shaft to ensure
that there are no binding in the pump.
43. Torque the nuts (1), in a criss-cross pattern,

to 200 lb ft (270 Nm).

9 - 20 - 22 M4309202
Section 9 Group 20
20.3 Dual Section SPI Pump

The dual section SPI pump consist of two integrated
pump sections and a priority valve section.
The SPI pump is mechanically driven by a hydraulic

motor that is part of the primary hydraulic circuit.
The SPI pump is used for delivery of hydraulic flow to

the loader stabilizers and optional power beyond
functions.
1. Dual Section SPI Pump

2. Bolt
3. Flat Washer
4. Lock nut
5. Flange Mounting Kit
6. Adapter
7. O-ring
8. Test Port Fitting Assembly
20.3.2 Removal
CAUTION
Important!
after removal to prevent components from becoming
hydraulic system can lead to premature equipment
failure.
1. Close hydraulic tank ball valve (1).
Component Number 2122 9 - 20 - 23

M4309203
Group 20 Section 9
20.3.2 Removal
2. Through the access cut-out in the frame member,

loosen set-screw (2) securing SPI drive shaft (3) to
the SPI motor.
3. Remove pilot hose (4) and tank return hose (5) from
pump assembly (6). Plug the hoses and pump ports.
4. Remove four bolts (7) securing two half flanges (8)

and inlet hose (9) to pump assembly (6). Remove
and discard O-ring (10).
5. Remove outlet hose (11) from pump assembly (6).

Plug the hose and pump port.
9 - 20 - 24 Component Number 2122

M4309203
Section 9 Group 20
20.3.2 Removal
CAUTION
The hydraulic pump assembly is heavy: use
appropriate support and lifting equipment to
prevent personal injuries or equipment damage
when removing the pump assembly from the loader
base frame.
6. Place appropriate support under hydraulic pump

assembly (6), and remove four lock nuts (12), flat
washers (13), and bolts (14) securing the pump
assembly to the loader base frame.
7. Carefully lower the hydraulic pump assembly clear of

the loader base frame, being careful not to snag the
SPI drive shaft inside the electric slip ring.
8. Place the pump assembly on a workbench and

remove adapter (15) from primary pump
section (16). Remove and discard O-ring (20).
9. Remove the test port fitting assembly (17) from the

priority valve fitting (18).
10. Loosen set screw (19) and remove drive shaft (3)
from the pump assembly.

M4309203
Group 20 Section 9
20.3.3 Installation
1. Install new O-ring (20) on adapter (15) and install the
adapter in the outlet port in the primary pump
section (16).
2. Install test port fitting assembly (17) on priority valve

fitting (18).
3. Install SPI drive shaft (3) on the pump input shaft

and tighten set screw (19).
CAUTION
The hydraulic pump assembly is heavy: use
appropriate support and lifting equipment to
prevent personal injuries or equipment damage
when installing the pump assembly on the loader
base frame.
4. Using appropriate lifting device and support,

carefully slide the SPI drive shaft through the electric
slip ring and position hydraulic pump (6) in assembly
position with the loader base frame. Ensure that the
SPI drive shaft engages properly with the SPI motor
output shaft.
5. Install four bolts (14), flat washers (13), and lock

nuts (12) to secure the pump assembly. Torque the
lock nuts to 90 to 100 lb ft (122 to 136 Nm).

M4309203
Section 9 Group 20
20.3.3 Installation
8. Tighten drive shaft set screw (2) to secure SPI drive

shaft (3) to the SPI motor output shaft.
9. Install pilot hose (4), tank return hose (5), and outlet
hose (11) onto pump assembly (6).
10. Install new O-ring (10) on inlet hose (9).
11. Install four bolts (7) to secure the inlet hose and two
half flanges (8), to pump assembly (6).
Note!
If the pump has been rebuilt or otherwise requires
testing and adjustment, refer to Section 5 of this manual.
12. Open hydraulic tank ball valve (1), operate the SPI
pump, and check for leaks.

M4309203
Section 9 Group 20
20.4 Dual Section SPI Pump Repair

Dirt or contamination induced in any hydraulic To prevent damage to machined surfaces, be cautious
component or system is a major cause of premature when using pry bars or securing any part of the
failure. Therefore, strict cleanliness should be exercised hydraulic pump in a vice. Use protective vice caps
when the pump is removed or installed on the vehicle whenever necessary.
and during repair of the unit on the bench. Whenever a
hydraulic line is disconnected or a component is opened The hydraulic pump must be driven in the direction of
up, ensure that exposed hose ends or ports are capped rotation for which it was built; otherwise, pressure will
immediately. This not only protects against blow the shaft seals. Use identifying markings wherever
contamination but also reduces unwanted hydraulic fluid necessary during disassembly to ensure that all parts
spill. When components are disassembled, ensure that are assembled exactly as disassembled.
they are completely cleaned and wiped with clean
lintless cloth before being assembled.
20.4.2 Dual Section SPI Pump Components

1. Straight Connector 25. Hex Head Bolt
2. O-ring 26. Pump Cover
3. O-ring 27. Channel Seal
4. Plug 28. Thrust Plate
5. Elbow 29. Drive Gear - Pilot Pump
6. O-ring 30. Driven Gear - Pilot Pump
7. Plug 31. Gasket Seal
8. O-ring 32. Pilot Pump Gear Housing
9. Priority Valve Spool 33. Hex Nut
10. Relief Valve 34. Flat Washer
11. Priority Valve Housing 35. Pump Base Cover
12. Priority Valve Spring 36. Connecting Shaft
13. O-ring 37. Channel Seal
14. Plug 38. Thrust Plate
15. Jam Nut 39. Driven Gear - Primary Pump
16. Screw Fitting 40. Drive Gear - Primary Pump
17. O-ring 41. Gasket Seal
18. O-ring 42. Primary Pump Gear Housing
19. Backup Ring 43. Stud
20. Adjustment Screw 44. Shaft End Cover
21. Retaining Ring 45. Double Lip Seal
22. Hex Nut 46. Bearing
23. Flat Washer 47. Retaining Ring
24. Stud

M4309204 9 - 20 - 28
Group 20 Section 9
20.4.2 Dual Section SPI Pump Components

9 - 20 - 29 M4309204
Section 9 Group 20

20.4.3.1 Pilot Pump
1. Place the pump on a work bench and match mark

the sections to ensure correct reassembly.
Important!
Do not clamp on any machined surfaces to hold the
pump components during disassembly.
2. Remove two hex nuts (1) and flat washers (2)

securing priority valve (3) to pump cover (4).
3. Slide priority valve (3) off two studs (5). Remove and
discard O-rings (6).
4. Remove two bolts (7), four nuts (8), and flat

washers (9) and slide pump cover (4) off two
studs (5).
5. Remove two studs (5) from pump base cover (10).

M4309204 9 - 20 - 30
Group 20 Section 9

20.4.3.1 Pilot Pump Cont.
6. Remove thrust plate (11) and gasket seal (12) from

pilot pump gear housing (13). Remove channel
seal (14) from the thrust plate.

gear (16) from the pilot pump gear housing (13).
8. Remove thrust plate (17) from the face of pump

base cover (10) and remove channel seal (18) from
the thrust plate.
9. Carefully lift or pry off the pilot pump gear

housing (13), being careful not to damage contact
face or edges of the gear housing or pump base
cover (10). Remove gasket seal (19) and discard.

9 - 20 - 31 M4309204
Section 9 Group 20

20.4.3.2 Primary Pump
10. Remove four nuts (20) and flat washers (21) from
studs (22)
11. Lift or pry off pump base cover (10) from the primary
pump gear housing (23), being careful not to
damage contact face or edges of the pump base
cover or the primary pump gear housing.
12. Remove connecting shaft (24) from primary pump

drive gear (25).
13. Remove thrust plate (26), and gasket seal (27) from
the primary pump gear housing (23) and remove
channel seal (28) from the thrust plate. Discard
channel and gasket seals.

gear (29) from the primary pump gear housing (23).
15. Remove thrust plate (30). Remove and discard

channel seal (31) from the thrust plate.

M4309204 9 - 20 - 32
Group 20 Section 9
20.4.3 Disassembly
20.4.3.2 Primary Pump Cont.
16. Lift the primary pump gear housing (23) from shaft
end cover (32). If prying is necessary, be careful not
to damage the machined surfaces. Remove gasket
seal (33) and discard.
17. Remove four studs (22) from shaft end cover (32).
18. With the pump mounting flange facing up, secure

shaft end cover (32) in a vise and remove bearing
retaining ring (34).
19. Using a suitable bearing puller, remove bearing (35).
20. Using special seal removal tool, ref. Paragraph 20.7

for tool details, and ball peen hammer, carefully
remove and discard double lip seal (36).

9 - 20 - 33 M4309204
Section 9 Group 20

Clean all disassembled parts and inspect applicable
components for wear and damage as detailed in
paragraph 20.5.
20.4.4.1 Primary Pump
1. Smothen all flat machined surfaces using a medium

grit carborundum stone and rinse the parts in
cleaning solvent. Air blast and, using clean lintless
cloth, wipe all parts dry before starting assembly.
2. Check that dowel sleeves (37) are installed in pump

sections as applicable. If required, install new dowel
sleeves using a soft faced hammer, ensuring that
the sleeves are started straight and lightly tapped in
place.
3. Coat mating surfaces of new double lip seal (36) and

the recessed bore in shaft end cover (32) with
Permatex Aviation Form-A-Gasket No. 3
4. With the metal side of the new double lip seal (36)
facing up, and using an arbor press and special bar,
ref. Paragraph 20.7 for tool details, press the double
lip seal into the recessed bore in shaft end
cover (32) until it seats flush with the edge of the
recess. Wipe off excess sealant.

M4309204 9 - 20 - 34
Group 20 Section 9

5. Using a soft faced hammer and brass drift punch,

install bearing (35) into the bore in shaft end cover
(32), ensuring that the bearing seats fully against the
recess at the bottom of the bore.
6. Install retaining ring (34) to secure bearing (35) in

place in the shaft end cover.
7. Apply grease to two gasket seals and install the

seals in the grooves on the primary pump gear
housing (23).
8. Position the primary pump gear housing (23) on

shaft end cover (32), making sure that assembly
markings on the casting exteriors match.
9. Using a soft faced hammer and making sure that

dowel sleves (37) align properly with the
coresponding holes, tap lightly on the primary pump
gear housing (23) until it seats tightly against shaft
end cover (32). Be careful not to pinch the gasket
seal.

9 - 20 - 35 M4309204
Section 9 Group 20

10. Install a new channel seal into the groove in each

primary pump thrust plate, ensuring that the concave
side of the channel seal faces the thrust plate.
11. Install thrust plate (30), with the channel seal facing
down, through primary pump gear housing (23) and
into place on shaft end cover (32), ensuring that the
thrust plate relief groove faces the outlet side of the
pump.
12. Insert driven gear (29) in the primary pump gear

housing (23) and into the bore in shaft end
cover (32).
Important!
The lips of the new double lip seal may be damaged if
the seal is installed without the use of the special sleeve
tool.
13. Coat the special sleeve tool (A) with grease, ref.
Paragraph 20.7 for tool details, and insert the shaft
of driving gear (25) in the tool.
14. With a twisting motion, push the sleeve tool

carefully through the double lip seal until the teeth of
drive gear (25) mesh with the teeth of driven
gear (29). Apply oil to the teeth of both gears.

M4309204 9 - 20 - 36
Group 20 Section 9

15. Install four studs (22), through the dowel sleeves in

primary pump gear housing (23), into shaft end
cover (32).

plate (26) into the bore of primary pump gear
housing (23), ensuring that the thrust plate relief
groove is facing the outlet side of the gear housing.
17. Insert connecting shaft (24) into the primary pump

drive gear (25).
18. Align the journals of drive gear (25) and driven

gear (29) with the bores in pump base cover (10).
Slide the pump base cover over the four studs (22)
and onto the primary pump gear housing (23).
19. Using a soft faced hammer, carefully tap on pump

base cover (10) until it is fully seated, being careful
not to pinch the gear housing gasket seal. Ensure
that assembly markings on the casting exteriors
match.
20. Install the four hex nuts (20) and flat washers (21) on
studs (22) and snug up the nuts.
21. Turn the pump drive gear shaft to ensure that there
is no binding in the primary pump and torque the
nuts to 200 lb ft (270 Nm).

9 - 20 - 37 M4309204
Section 9 Group 20

20.4.4.2 Pilot Pump
22. Install a new channel seal in the groove in each pilot

pump thrust plate, ensuring that the concave side of
the channel seal faces the thrust plate.
23. Apply grease to two new gasket seals and install the
seals in the grooves on the pilot pump gear
housing (13).
24. Check that dowel pins (38) are installed in pump

sections as applicable. Use a soft faced hammer if
installation of new dowel pins is required. Ensure
that any new dowel pin is started straight and lightly
tapped in place.
25. Position the pilot pump gear housing (13) on the

pump base cover (10), making sure that assembly
markings on the casting exteriors match, and that
dowel pins (38) align with corresponding dowel
holes.

M4309204 9 - 20 - 38
Group 20 Section 9

26. With the channel seal facing down, install thrust

plate (17) into place on base cover (10), ensuring
that the thrust plate relief groove faces the outlet
side of the pump.
27. Insert driven gear (16), through gear housing (13),

into the bore in base cover (10).
28. Install drive gear (15) onto the splined connecting

shaft in the bore of base cover (10). Apply oil to the
teeth of both gears.

plate (11) into the bore of gear housing (13). Ensure
that the thrust plate relief groove is facing the outlet
side of the gear housing.
30. Install pump cover (4) on gear housing (13),

ensuring that assembly markings on the casting
exteriors align.
31. Using a soft faced hammer, tap on the pump cover

until it seats tightly against the gear housing.
32. Install two studs (5), through pump cover (4) and
gear housing (13), into base cover (10).
33. Install two bolts (7), nuts (8), and four flat
washers (9). Tighten the bolts and nuts snug.
34. Turn the pump input shaft to ensure that there is no

binding in the pilot pump and torque the bolts and
nuts to 200 lb ft (270 Nm).

9 - 20 - 39 M4309204
Section 9 Group 20

35. Install two new O-rings (6) in the ports in pump

cover (4) and slide the priority valve assembly (3)
onto the two studs (5).
36. Install two nuts (1) and flat washers (2) to secure the
priority valve assembly (3) to pump cover (4).
Torque the nuts to 67 lb ft (91 Nm).

M4309204 9 - 20 - 40
Group 20 Section 9
20.4.5 Priority Valve Disassembly
1. Remove the priority valve from the SPI pump as

detailed in Paragraph 20.4.3.
2. Secure the priority valve housing (1) in a vise and

remove plug (2), spring (3), plug (4) and priority
valve spool (5). Discard O-rings (6 and 7).
3. Remove jam nut (8), screw fitting (9), adjustment

screw (10), O-ring (11), backup ring (12), and
O-ring (13). Discard the O-rings.
Note!
If the adjustment screw is replaced, retaining ring (14)
should also be replaced.
Important !
The relief valve is factory adjusted! No attempt should
be made to disassemble or repair this valve. If the relief
valve is malfunctioning, it should be replaced.
5. Remove relief valve (15) from priority valve

housing (1).
6. Remove fitting (16), O-ring (17), plug(18),

O-ring (19), elbow (20), and O-ring (21) from the
priority valve housing.

9 - 20 - 41 M4309204
Section 9 Group 20
20.4.6 Priority Valve Assembly

1. Secure the priority valve housing (1) in a vise and
install adapter fitting (16), O-ring (17), plug (18),
O-ring (19), elbow (20), and O-ring (21) in the valve
housing.
2. Install relief valve (15) in the priority valve housing.
3. Install new O-ring (13) on screw fitting (9) and,

ensuring that the retaining ring (14) is in place on
adjustment screw (10), install the adjustment screw
in the screw fitting.
4. Install O-ring (11), backup ring (12), and screw

fitting (9) in the priority valve housing (1).
Note!
Final adjustment of priority flow should be performed
after the pump assembly is installed on the loader. Refer
to Section 5.
5. Install jam nut (8) on adjustment screw (10) and turn

the adjustment screw clockwise until it bottoms out
inside the priority valve housing, then back off 1/8 to
1/4 turn and tighten the jam nut.
6. Install a new O-ring (6) on plug (2) and a new

O-ring (7) on plug (4).
7. Insert the priority valve spool (5) and spring (3) in the
valve housing (1) and install the plugs (2 and 4).
8. Install the priority valve on the SPI pump as detailed

in Paragraph 20.4.4.

M4309204 9 - 20 - 42
Section 9 Group 20
20.5 Inspection and Parts Replacement
To establish how much wear may be sustained before

parts replacement is required the following suggestions
should be used as a guideline.
Gear Housings:
Wear in excess of 0.007 in. (0.18 mm) cut-out

necessitates replacement of the gear housing. To
measure this, place a straight-edge across the bore. If
a 0.007 in. (0.18 mm) feeler gauge can be inserted
under the straight-edge in the cut-out area, the gear
housing should be replaced.
Pressure pushes the gears against the housing on the

low pressure side. As the hub and bushings wear, the
cut-out becomes more pronounced. Excessive cut-out in
a short period of time indicates excessive pressure or oil
contamination. Withdraw a fluid sample for analysis and
check the tank for dirt. Where cut-out is moderate,
0.007 in. (0.18 mm) or less, the gear housing may be
considered in good condition and reused.
Gears:
Any scoring on the gear hubs necessitates replacement.

Scoring, grooving, or burring of the outside diameter of
the gear teeth requires replacement. Nicking, grooving,
or fretting of teeth surfaces also require gear
replacement.
Drive Shafts:
Replace the drive shaft if there is any wear detectable

by touch in the seal area or at the drive coupling.
0.002 in. (0.51 mm) wear is the maximum allowable.

M4309205 9 - 20 - 43
Group 20 Section 9
Thrust Plates:
The thrust plates seal the gear section at the sides of

the gears. Wear in these areas will allow internal
slippage, i.e., oil will bypass within the pump.
A maximum of 0.002 in. (0.51 mm) wear is allowable.

Replace the thrust plates if they are scored eroded or
pitted.
Check the center of the thrust plates where the gears

mesh. Erosion in this area indicates oil contamination.
Pitted thrust plates indicate cavitation or fluid aeration.
Discolored thrust plates indicate overheating, caused,

most probably, by insufficient fluid.
Seals and Gaskets:
Replace all rubber and polymer seals, including all

O-rings, thrust plate channel seals, shaft seals, and
gasket seals.

9 - 20 - 44 M4309205
Section 9 Group 20
Dowel Pins: Plugs:
If either the dowel or dowel hole is damaged, the dowel Ensure that the plugs in the shaft end and port end
or machined casting, or both, must be replaced. covers are in place. The plugs are not subject to wear
and should not be touched if they appear to be properly
If more than reasonable force is required to seat the installed.
dowels, the cause may be poorly deburred or dirty parts,
cocking of the dowel in the dowel hole, or improper
pin-to-hole fit.
Bushings:
The bushings are not separately replaceable. If the

gears are replaced the machined castings containing the
bushings, i.e., bearing cover and end cover sections,
must also be replaced.

M4309205 9 - 20 - 45
Group 20 Section 9
20.6 Recommended Start-up Procedure
Before operating a new or rebuilt pump, back off the

hydraulic system main relief valve, see Section 5, until
the spring tension on the adjusting screw is relieved.
Reducing the relief pressure should reduce the
possibility of immediate damage to the replacement
pump in case the relief valve setting was increased
beyond the recommended operating pressure prior to
removing the old pump.
11843a
Start and operate the pump at least two minutes at no
load and at low rpm (minimum 400 rpm). During this
break-in period, the pump should run free and not
develop any excess heat. If the pump operates properly,
speed and pressure can be increased to normal
operating settings.
Reset the main relief valve to its proper setting, refer to

Section 5, while the pump is running at maximum
operating speed.
11890

9 - 20 - 46 M4309205
Section 9 Group 20
20.7 Special Tools
Availability of the special tools shown is essential for

repair of the main and the SPI pumps. Manufacture the
tools locally as per detailes provided. All dimensions are
in inches.
Seal Removal Tool
This tool can be manufactured from an old screwdriver.
Heat the tip of the screwdriver and bend it as shown.

Grind the tip as required.
Special Steel Sleeve - Triple Section Main Pump
Manufacture the steel sleeve from mild steel bar stock.
Special Steel Sleeve - Dual Section SPI Pump
Manufacture the steel sleeve from mild steel bar stock.

M4309207 9 - 20 - 47
Group 20 Section 9
20.7 Special Tools
O-Ring Installation Tool
Manufacture the O-ring installation tool from mild steel

bar stock.
O-Ring Insertion Tool
This insertion tool can be manufactured from suitable

steel tubing or mild steel bar stock.
Seal Installation Bar
Manufacture the bar from mild steel bar stock.

9 - 20 - 48 M4309207
Section 9 Group 20
20.8 Pilot Pump

The pilot pump is a single, unidirectional, gear pump The hydraulic flow developed by the pilot pump is used
driven by the engine either through direct gear drive or to operate the pilot controlled spools in the main system
by belt and pulley. control valves.
20.8.2 Removal/Installation - Engine Mounted Pump (Cummins)
1. Pilot Pump 4. Flat Washer

2. Gasket 5. O-ring
3. Bolt 6. Elbow

M4309208 9 - 20 - 49
Group 20 Section 9
20.8 Pilot Pump
20.8.2 Removal/Installation - Engine Mounted Pump (Cummins) Cont.
Important!
after removal to prevent components from becomming
contaminated. Contamination introduced in the hydraulic
system can lead to premature equipment failure.
All items are accessible from the rear side of the engine
compartment.
Shut-off the hydraulic tank pilot supply valve.
Remove the outlet and inlet hoses (1 and 2) from pilot

pump (3). Cap the open hose ends and fittings
immediately to prevent contamination of the hydraulic
components and to reduce spill.
Remove two bolts (4) and flat washers (5) securing the
pilot pump to the engine.
Remove the pilot pump and gasket (6) from the engine.
Discard the gasket.
Note!
Re-use of gasket (6) is not recommended.
CAUTION
Attach a DO NOT START warning tag to the ignition Install the pilot pump in reverse order of removal and
key or a control lever before undertaking work on torque the two mounting bolts to 48 lb ft (65 Nm).
while the hydraulic system is disabled can result in Open the hydraulic tank pilot supply valve before
personal injuries and equipment damage. attempting to start the engine.

9 - 20 - 50 M4309208
Section 9 Group 20
20.8 Pilot Pump
20.8.3 Removal/Installation - Belt Driven Pump (John Deere)
1.Pilot Pump 7. O-ring

2. Bolt 8. Elbow
3. Flat Washer 9. Pulley
4. Mounting Bracket 10. Tapered Bushing
5. Flat Washer 11. Bolt
6. Lock Nut 12. Flat Washer

M4309208 9 - 20 - 51
Group 20 Section 9
20.8 Pilot Pump
20.8.3 Removal/Installation - Belt Driven Pump (John Deere) Cont.
Important!
CAUTION Cap hydraulic ports, hoses, and fittings immediately
Attach a DO NOT START warning tag to the ignition after removal to prevent components from becomming
key or a control lever before undertaking work on contaminated. Contamination introduced in the hydraulic
the hydraulic system. Attempts to run the engine system can lead to premature equipment failure.
personal injuries and equipment damage. Remove outlet and inlet hoses (1 and 2) from pilot
pump (3). Cap the open hose ends and fittings
immediately to prevent contamination of the hydraulic
All items are accessible from underneath the engine or components and to reduce spill.
the rear side of the engine compartment.
Loosen two bolts (4) and lock nuts (5) securing the pilot
Shut-off the hydraulic tank pilot supply line valve. pump to bracket (6), adjust the pump position and
remove V-belt (7).

9 - 20 - 52 M4309208
Section 9 Group 20
20.8 Pilot Pump
20.8.3 Removal/Installation- Belt Driven Pump (John Deere) Cont.
Remove the three bolts (8) and flat washers (9) securing surface of tapered bushing and a light coate of
tapered bushing (10) to pulley (11). Anti-seize compound is applied to both surfaces.
Install two of the removed bolts in the two threaded Install the pilot pump in reverse order of removal.
holes in the tapered bushing and alternately screw the
bolts clockwise until the bushing is released from the When installing the pulley and tapered bushing, apply
pulley. Remove the tapered bushing and the pulley from LoctiteTM 242 to the thread of bolts (8). Tighten the bolts
the pilot pump. to 20 lb ft (27 Nm).
Remove two lock nuts (5), flat washers (12), and When installing the pilot pump, torque the mounting
bolts (4) securing pilot pump (3) to bracket (6). bolts and lock nuts to 40 lb ft (54 Nm).
Before installing a new or repaired pilot pump, ensure Open the hydraulic tank pilot supply valve before
that surface rust is removed from the bore and tapered attempting to start the engine.

M4309208 9 - 20 - 53
Group 20 Section 9
20.9 Pilot Pump Repair
Because the replacement cost of the complete pilot

pump is relative low, it is not recommended that major
repair is undertaken.
Repair of the pilot pump should be limited to

replacement of a leaking shaft seal should such a failure
occur.
Pilot Pump - Engine Mounted (Cummins)
1. Pilot Pump
2. External O-ring
3. Shaft Lip Seal
4. Retaining Ring
Pilot Pump - Belt Driven (John Deere)
1. Pilot Pump
2. Square Shaft Key
3. Shaft Lip Seal
4. Retaining Ring

9 - 20 - 54 M4309208
Section 9 Group 20
20.10 Swing Gear Motor

The Swing gear motor is a single, bidirectional, gear
motor driven by flow from the primary hydraulic system.
The hydraulic flow to the swing gear motor is directed

through the main control valve and manually controlled
by means of the foot control in the cab.
1. Swing Gear Motor

2. Elbow - 90 Deg. with test port
3. O-ring
4. O-ring
5. Adapter
6. O-ring
7. Flat Washer
8. Bolt
20.10.2 Removal
CAUTION
Important!
1. Tag the two hydraulic hoses (1) to ensure correct

reassembly. Remove the hoses and two elbows (2)
from hydraulic motor (3). Cap the open hose ends
and motor ports immediately to prevent
contamination and to reduce spill. Remove and
discard the two O-rings (4).
2. Remove the case drain hose (5) and adapter (6)

from the hydraulic motor. Cap the open hose end
and motor port. Remove and discard O-ring (7).

M4309211 9 - 20 - 55
Group 20 Section 9
20.10 Swing Gear Motor
20.10.2 Removal
3. Remove the two hex head bolts (8) and flat
washers (9) securing the hydraulic motor to the
swing gear box.
4. Using a soft faced hammer, break the paint bond

between the hydraulic motor and the swing gear
box. Remove the hydraulic motor and O-ring (10)
from the swing gear box. Discard the O-ring.
20.10.3 Installation
1. Install hydraulic motor (3) and new O-ring (10) on
the swing gear box.
2. Apply LoctiteTM 242 to the thread of two bolts (8).

Install the bolts together with two flat washers (9) to
secure the hydraulic motor to the swing gear box.
Torque the bolts to 90 lb ft (120 Nm).
3. Install adapter (6) and new O-ring (7), in hydraulic

motor (3) and install the case drain hose (5).
4. Install two elbows (2) an new O-rings (4) onto the

hydraulic motor and install two hydraulic hoses (1)
onto the elbows. Ensure that the hoses are installed
as tagged during disassembly.

9 - 20 - 56 M4309211
Section 9 Group 20
20.11 Swing Gear Motor Repair

Dirt or contamination induced in any hydraulic To minimize the risk of damage to any components as
component or system is a major cause of premature well as reduce the time to perform repair to the motor, it
failure. Therefore, strict cleanliness should be exercised is recommended that the special manufactured tools,
when the motor is removed or installed on the vehicle mentioned in the disassembly and assembly
and during repair of the unit on the bench. Whenever a procedures, be made available. See Paragraph 20.15.
hydraulic line is disconnected or a component is opened
up, ensure that exposed hose ends or ports are capped To prevent damage to machined surfaces, be extra
immediately. This not only protects against careful when using pry bars or securing any part of the
contamination but also reduces unwanted hydraulic fluid hydraulic motor in a vice. Use protective vice caps
spill. When components are disassembled, ensure that whenever necessary.
they are completely cleaned, air blasted, and wiped with
clean lintless cloth before being assembled. Use identifying markings wherever necessary during
disassembly to ensure that all parts are assembled
exactly as disassembled.

M4309211 9 - 20 - 57
Group 20 Section 9
20.11.2 Swing Gear Motor Components
1. Bolt 9. Drive Gear

2. Flat Washer 10. Dowel Pin
3. Port End Cover 11. Shaft End Cover
4. Thrust Plate Seals 12. Lip Seal
5. Thrust Plate 13. Seal Retainer
6. Gasket Seal 14. Ball Bearing
7. Gear Housing 15. Retaining Ring
8. Driven Gear

9 - 20 - 58 M4309211
Section 9 Group 20
20.11.3 Disassembly
1. Place the motor on a suitable work bench and match
mark the sections to ensure correct reassembly.
Important!
Do not clamp on any machined surface to hold the
motor components during disassembly.
2. Remove the four bolts (1) and flat washers (2) that
secure the motor sections together.
Note!
Dowel pin are used between the end covers and gear
housing. These dowel pins should not be removed but
left installed in the components they are secured in.
3. Lift port end cover (3) off gear housing (4), being
careful not to damage the machined surfaces.
4. Remove thrust plate (5) and gasket seal (6) from the
gear housing and remove seals (7) from the thrust
plate. Discard all seals.

M4309211 9 - 20 - 59
Group 20 Section 9
20.11.3 Disassembly
gear (9) from gear housing (4). Avoid tapping the
gear teeth together or against other hardened
surfaces. The two gears are a matched set and
should be kept together.
6. Remove thrust plate (10) and remove seals (11)

from the thrust plate. Discard all the seals.
7. Remove gear housing (4) from shaft end cover (12),

being careful not to damage the machined surfaces.
Remove and discard gasket seal (13).
8. Secure shaft end cover (12) in a vise, with the

mounting flange facing up, and remove retaining
ring (14).
9. Remove ball bearing (15) and seal retainer (16).
10. Using a special seal removal tool and a hammer,

refer to Paragraph 20.15 for tool details, carefully
remove seal (17) from shaft end cover (12). Discard
the seal.
11. Clean all disassembled parts and inspect applicable

components for wear and damage, refer to
paragraph 20.14.

9 - 20 - 60 M4309211
Section 9 Group 20
20.11.4 Assembly

Important!
The plugs installed in the shaft end cover and port end
cover should not be removed or replaced.
2. Check that dowel pins (18) are installed in applicable

motor sections. Use a soft faced hammer to lightly
tap missing dowel pins in place. Ensure that new or
loose dowel pins are installed straight.
3. Coat mating surfaces of new lip seal (17) and the

recessed bore in shaft end cover (12) with Permatex
Aviation Form-A-Gasket No. 3
4. With the metal side of the new lip seal (17) facing
up, and using an arbor press and special bar, refer
to Paragraph 20.15 for tool details, press the lip seal
into the recessed bore in shaft end cover (12) until it
seats flush with the edge of the recess. Wipe off
excess sealant.

M4309211 9 - 20 - 61
Group 20 Section 9
20.11.4 Assembly
5. Install seal retainer (16), ball bearing (15) and

retaining ring (14) in shaft end cover (12).
6. Apply grease to two new gasket seals and insert the

seals in the grooves in the gear housing.
7. Install new seals into the thrust plates, ensuring that

the concave side of each seal faces into the groove
in the thrust plate.

9 - 20 - 62 M4309211
Section 9 Group 20
20.11.4 Assembly
8. Position gear housing (4) on shaft end
cover (12), making sure that dowel pins (18), the
corresponding dowel holes, and the assembly
9. Using a soft faced hammer, tap lightly on gear

housing (4) until it seats tightly against shaft end
cover (12), being careful not to pinch the gear
housing gasket seal in the process.
10. With the seals facing down, insert thrust plate (10),
onto shaft end cover (12). Ensure that the relief
groove in the thrust plate faces the inlet side of the
motor.
11. Insert driven gear (9) in the gear housing (4) and into
the bore in shaft end cover (12).
Important!
If installed without using the special sleeve tool, the lips
of the new double lip seal may easily be damaged.
12. Coat the special sleeve tool (A) with grease, refer to
Paragraph 20.15 for tool details, and place the
splined end of driving gear (8) inside the sleeve.
13. With a twisting motion, carefully push the sleeve

tool (A) through the lip seal in the shaft end cover
until the teeth of driving gear (8) mesh with the teeth
of driven gear (9). Apply oil to the teeth of both gears.

M4309211 9 - 20 - 63
Group 20 Section 9
20.11.4 Assembly
14. With the seals facing up, install thrust plate (5) over
the journals of gears (8 and 9), ensuring that the
thrust plate relief groove is facing the inlet side of
gear housing (4).
15. Align the journals of gears (8 and 9) with the bores in

port end cover (3) and install the port end cover on
gear housing (4). Ensure that assembly markings on
the casting exteriors align.
16. Ensure that the dowel pins engage with the

corresponding holes and, using a soft faced
hammer, tap on port end cover (3) until it seats
tightly against gear housing (4).
17. Install four flat washers (2) and hex head bolts (1) to
secure the motor sections together. Tighten the bolts
snug.

ratchet handle, rotate the motor drive shaft to ensure
that there are no binding in the motor.
19. Torque the four bolts (1) to 200 lb ft (270 Nm).

9 - 20 - 64 M4309211
Section 9 Group 20
20.12 SPI Motor

The SPI motor is a single, unidirectional, gear motor The SPI motor is used to drive the SPI pump in the
driven by flow from the primary hydraulic system. lower hydraulic system.
The flow to the SPI motor is directed from either the

main or the jib control valve.
1. Tee-fitting 8. Flange Kit

2. O-ring 9. Flanged Elbow - 90 Deg.
3. Adaptor Flange 10. Elbow - 90 Deg.
4. Socket Head Setscrew 11. O-ring
5. O-ring 12. Adaptor
6. SPI Motor 13. Bolt
7. O-Ring 14. Lock Nut

M4309212 9 - 20 - 65
Group 20 Section 9
20.12 SPI Motor
20.12.2 Removal
CAUTION
Important!
1. Through the access cut-out in the frame member,

loosen set-screw (1) that secures the SPI drive
shaft (2) to the SPI motor (3).
2. Remove the outlet hose (4) and the two inlet hoses
(5 and 6) from the SPI motor (3). Cap the open hose
ends and fittings immediately to prevent
contamination of the hydraulic components and to
reduce spill.
3. Disconnect the case drain tube/hose (7) from the

SPI motor and cap the tube/hose end as well as the
motor fitting.
4. Remove the four lock nuts (8) and bolts (9) that
secure the SPI motor (6) to the electric swivel (10).

9 - 20 - 66 M4309212
Section 9 Group 20
20.12 SPI Motor
20.12.2 Removal
1. If removed, clean the motor inlet and outlet fiittings

CAUTION thoroughly.
The SPI motor assembly is heavy! Use appropriate
support and lifting equipment to prevent personal 2. Using new O-ring seals, install the inlet, outlet and
injuries or equipment damage when removing the case drain fittings onto the SPI motor.
motor assembly from the loader.
3. Using appropriate lifting device and support,
carefully install the SPI motor on the loader, making
5. Using lifting equipment as necessary, carefully sure that the drive shaft slides onto the motor output
remove the SPI motor assembly from the loader. shaft.
Note!
The inlet and outlet fittings installed in the SPI motor can
remain installed in the motor port end cover unless
replacement of the seals or the SPI motor is required.
6. Place the motor assembly on a workbench and, if

required, remove the inlet and outlet fittings from the
motor.
7. Remove and discard all O-ring seals.
CAUTION 4. Install the four bolts (9) and new lock nuts (8) to
The SPI motor assembly is heavy! Use appropriate secure the the SPI motor to electrical swivel (10).
support and lifting equipment to prevent personal
injuries or equipment damage when installing the 5. Install the case drain tube/hose (7) onto the SPI
motor on the loader. motor Fitting.

M4309212 9 - 20 - 67
Group 20 Section 9
20.12 SPI Motor
6. Install the two inlet hoses (5 and 6) onto the motor
inlet tee-fitting and the outlet hose (4) onto the
motor outlet elbow, making sure that all three hose
connections are securely tightened.
7. Torque bolts (9) to 90 to 100 lb ft. (122 to 136 Nm).
8. Tighten set-screw (1) to secure the SPI drive shaft

(2) on the motor output shaft.

9 - 20 - 68 M4309212
Section 9 Group 20
20.13 SPI Motor Repair
To minimize the risk of damage to any components as

20.13.1 General Information well as reduce the time to perform repair to the motor, it
is recommended that the special tools, mentioned in the
Dirt or contamination induced in any hydraulic disassembly and assembly procedures, be made
component or system is a major cause of premature available. Refer to Paragraph 20.15.
failure. Therefore, strict cleanliness should be exercised
when the motor is removed or installed on the vehicle To prevent damage to machined surfaces, be extra
and during repair of the unit on the bench. Whenever a carefull when using pry bars or securing any part of the
hydraulic line is disconnected or a component is opened hydraulic motor in a vice, use protective vice caps
up, ensure that exposed hose ends or ports are capped whenever necessary.
immediately. This not only protects against
contamination but also reduces unwanted hydraulic fluid The hydraulic motor must be driven in the direction of
spill. When components are disassembled, ensure that rotation for which it was built; otherwise, pressure will
they are completely cleaned, air blasted, and wiped with blow the shaft seals. Use identifying markings wherever
clean lintless cloth before being assembled. necessary during disassembly to ensure that all parts
are assembled exactly as disassembled.

M4309213 9 - 20 - 69
Group 20 Section 9
20.13.2 SPI Motor Components
1. Bolt 8. Driven Gear

2. Flat Washer 9. Shaft End Cover
3. Port End Cover 10. Dowel Bushing
4. Channel Seal 11. Shaft End Cover
5. Thrust Plate 12. Lip Seal
6. Gasket Seal 13. Spacer
7. Gear Housing 14. Retaining Ring

9 - 20 - 70 M4309213
Section 9 Group 20
20.13.3 Disassembly
1. Place the motor on a suitable work bench and match
mark the sections to ensure correct reassembly.
Important!
Do not clamp on any machined surface to hold the
motor components during disassembly.
2. Remove the four bolts (1) and flat washers (2) that
secure the motor sections together.
Note!
Dowel bushings are used between the end covers and
gear housing. These dowel bushings should not be
removed but left installed in the components they are
secured in.
3. Lift port end cover (3) off gear housing (4), being
careful not to damage the machined surfaces.
4. Remove thrust plate (5) and gasket seal (6) from the
gear housing and remove channel seal (7) from the

M4309213 9 - 20 - 71
Group 20 Section 9
20.13.3 Disassembly
5. Carefully remove drive gear (8) and driven gear (9)
from gear housing (4). Avoid tapping the gear teeth
together or against other hardened surfaces. The
two gears are a matched set and should be kept
together.
6. Remove thrust plate (10) and remove channel

seal (11) from the thrust plate. Discard the seal.
7. Remove gear housing (4) from shaft end cover (12),

being careful not to damage the machined surfaces.
Remove and discard gasket seal (13).
8. Secure shaft end cover (12) in a vise with the

mounting flange facing up and remove retaining
ring (14).
9. Remove spacer (15) and using a special seal

removal tool and a hammer, refer to Paragraph
20.15 for tool details, carefully remove seal (16) from
shaft end cover (12). Discard the seal.
10. Clean all disassembled parts and inspect applicable

components for wear and damage, refer to
paragraph 20.14.

9 - 20 - 72 M4309213
Section 9 Group 20
20.13.4 Assembly

Important!
The plugs installed in the shaft end cover and port end
cover should not be removed or replaced.
2. Check that dowel bushings (17) are installed in

applicable motor sections. Use a soft faced hammer
to lightly tap missing dowel bushings in place.
Ensure that new or loose dowel bushings are
installed straight.
3. Coat mating surfaces of new lip seal (16) and the

recessed bore in shaft end cover (12) with Permatex
Aviation Form-A-Gasket No. 3 non-hardening
sealant or equivalent.
4. With the metal side of new lip seal (16) facing up,
and using an arbor press and special bar, refer to
paragraph 20.15 for tool details, press the lip seal
into the recessed bore in shaft end cover (12) until it
seats flush with the edge of the recess. Wipe off
excess sealant.

M4309213 9 - 20 - 73
Group 20 Section 9
20.13.4 Assembly
5. Install spacer (15) and retaining ring (14) to secure

the spacer and seal in place in shaft end cover (12).
6. Apply grease to two new gasket seals and install the

seals in the grooves in the motor gear housing.
7. Install new channel seals into the two thrust plates,

Ensure that the concave side of each channel seal
faces into corresponding thrust plate groove.

9 - 20 - 74 M4309213
Section 9 Group 20
20.13.4 Assembly
8. Position gear housing (4) on shaft end cover (12),
making sure that dowel bushings (17), the
corresponding dowel holes, and the assembly
9. Using a soft faced hammer, tap lightly on the gear

housing until it seats tightly against the shaft end
cover, being careful not to pinch the gear housing
gasket seal in the process.
10. With the channel seal facing down, insert thrust

plate (10) onto shaft end cover (12). Ensure that the
relief groove in the thrust plate faces the inlet side of
the motor.
11. Insert driven gear (9), through gear housing (4), into
the bore in shaft end cover (12).
Important!
If installed without using the special manufactured steel
sleeve tool, the lips of the new double lip seal may be
damaged.
12. Coat the special sleeve tool (A) with grease, refer to
Paragraph 20.15 for tool details, and place the
splined end of driving gear (8) inside the sleeve.
13. With a twisting motion, carefully push the sleeve tool

(A) through the lip seal in the shaft end cover until
the teeth of driving gear (8) mesh with the teeth of
driven gear (9). Apply oil to the teeth of both gears.

M4309213 9 - 20 - 75
Group 20 Section 9
20.13.4 Assembly
plate (5) over the journals of gears (8 and 9),
ensuring that the thrust plate relief groove is facing
the inlet side of gear housing (4).
15. Install port end cover (3) on gear housing (4).

Ensure that assembly markings on the casting
exteriors align.
16. Using a soft faced hammer, tap on the port end

cover until it seats tightly against the gear housing.
17. Install four flat washers (2) and hex head bolts (1) to
secure the motor sections together. Snug up the
bolts alternately.

ratchet handle, rotate the motor drive shaft to ensure
that there is no binding in the motor.
19. Torque bolts (1) to 200 lb ft (270 Nm).

9 - 20 - 76 M4309213
Section 9 Group 20
The inspection procedures and the criteria for replacement of components in the Swing Gear Motor and the SPI
Motor are the same as the inspection procedures and parts replacement criteria for the Triple Section Main Pump
and SPI Pump detailed in Paragraph 20.5.

M4309214 9 - 20 - 77
Group 20 Section 9
20.15 Special Tools
The special tools required for repair of the Swing Gear Motor and the SPI Motor are also used for repair of the Triple
Section Main Pump and SPI Pump and detailed in Paragraph 20.7.

9 - 20 - 78 M4309214
Section 9 Group 20
20.16 Control Valves
20.16.1 General Information The lower SPI control valve is located between the
frame members of the lower frame and is accessible
The main, jib, and as applicable, lower SPI control valve when the forward deck plate is removed.
are used to control the hydraulic functions of the loader
and accessory equipment connected to the loader.
Note!
The main and jib valve banks are secured to the The control valves on hand may be different from the
underside of the loader superstructure and fully ones shown.
accessible from under neath the loader.
1. Main Control Valve

2. Jib Control Valve

M4309216 9 - 20 - 79
Group 20 Section 9
20.16 Control Valves
20.16.2 Removal
Use a high-boy jack or other suitable means to support
WARNING! the control valve and remove the three bolts securing the
Ensure that the loader booms and grapple are valve.
lowered and securely placed in supported position
before work is initiated on the hydraulic system. Clean the exterior of the valve thoroughly using solvent,
Failure to observe proper safety precautions can brush, and compressed air.
result in serious personal injury and equipment
damage.
CAUTION
personal injuries and equipment damage. 20.16.3 Installation
Using a high-boy jack or other suitable support, place
Important! the valve bank in assembly position with the loader
Cap hydraulic ports, hoses and fittings immediately after turntable or frame as applicable.
removal to prevent components from becoming
contaminated. Contamination introduced into the Apply LoctiteTM 242 to the threads of the three bolts used
hydraulic system can lead to premature equipment to secure the valve bank. Install the bolts with one flat
failure. washer each to secure the valve bank to the loader
frame. Torque the bolts to 90 to 100 lb ft (122 to 135 Nm).
Tag all hydraulic hoses connected to the control valve to
be removed to ensure correct installation. Remove the caps from the hose ends and port fittings,
one port and hose at the time, and install the hydraulic
Remove all hoses from the control valve, one at the hoses onto the valve bank as tagged during removal.
time. Cap the open hose end and valve port fitting
immediately to prevent contamination of the hydraulic Important!
components and to reduce spill. When installing a new solenoid coil with different colored
wires, ensure that the black wire is connected to ground.
If installed otherwise, a diode inside the coil may be
CAUTION! damaged.
The control valves are heavy! Use appropriate
support and lifting equipment to prevent personal Before the loader is returned to work, test and adjust the
injuries or equipment damage when removing any control valve relief pressure settings as detailed in
of the control valves from the loader. Section 5.

9 - 20 - 80 M4309216
Section 9 Group 20
20.17 Control Valve Repair
Note!
This procedure applies to the Main, Jib and Lower SPI 1. Using a waterproof, quick-drying marker, mark each
Control Valves. casting with a sequential number. Start by marking
the inlet casting as no. 1 and finish by marking the
outlet casting with the highest number.
20.17.1 Disassembly
2. Mark the port boss closest to the back cap on each
Place the control valve on a clean work bench and work section with a "B".
remove adapter fittings and O-rings from the valve
bank. Discard the O-rings. 3. Mark the port boss closest to the spool clevis end on
each work section with a "C".
Important!
The following steps are the most critical steps in the 4. Mark each relief valve with the number of the casting
disassembly procedure. They should be followed very to which it belong followed by the letter of the port
closely to ensure that the valve bank is properly boss at which it is located. Example "4B" and "4C".
reassembled when the repairs are completed.

M4309217 9 - 20 - 81
Group 20 Section 9
20.17.1 Disassembly Cont.

Control valves of different configurations have been requirements. The table and illustration below identify
used on the family of loaders to satisfy specific the most commonly used valves.
Item Description Where Used Serial Number

Cut-in
A SPI Lower Valve 330 & 430 SPI Machines CB1060

B SPI Lower Valve 330 & 430 SPI Machines 961354
C Main Control Valve 330 & 430 SPI with Joystick Cntrl CB1060
D Main Control Valve 330 & 430 SPI with 4-Stick Cntrl CB1060
E Main Control Valve 330 & 430 SPI with Joystick Cntrl 961314
F Main Control Valve 330 & 430 Swivel with J-stick Cntrl 961402
G Jib Control Valve 330 & 430 SPI with Joystick Cntrl CB1060
H Jib Control Valve 330 & 430 SPI with 4-Stick Cntrl CB1060
I Jib Control Valve 330 & 430 SPI with Joystick Cntrl 961314
J Jib Control Valve 330 & 430 Swivel with J-stick Cntrl 961402
K Delimber/Saw Control Valve 330 & 430 Swivel with J-stick Cntrl 961402
L Saw Cntrl Valve 330 & 430 Swivel with J-stick Cntrl 961402
A B
C D

9 - 20 - 82 M4309217
Section 9 Group 20
E F
G H
I J
K L

M4309217 9 - 20 - 83
Group 20 Section 9
1.Tie Bolt 20.17.2 Assembly

2. Flat Washer
3. Inlet Section Important!
4. Main Relief Valve Contamination introduced into the hydraulic system can
5. O-ring Seal (Kit) lead to premature equipment failure.
6. Lo-Boy Valve Section
7. Hi-Boy Valve Section To prevent contamination, wipe all components using
8. Port Relief Valve lintless cloth and blow out all valve passages using
9. O-Ring Seal compressed air.
10. Section Seals
11. Outlet Section Using new seal kit(s), install the relief valve(s) in
applicable valve section(s), ensuring that each relief
Remove the relief valve(s) from applicable valve valve is torqued to 80 to 90 lb ft (108 to 122 Nm).
section(s) and discard the relief valve seals.
Coat all new section seals with petroleum jelly or grease
Remove the four bolts securing the valve bank together and place the seals in the valve section grooves.
and discard the seals between the valve sections.
Assemble the valve sections on the four tie bolts in the
Replace or repair the valve section(s) as necessary, sequence marked during disassembly and torque the
refer to Paragraph 20.18. bolts, in a crisscross pattern, to 34 lb ft (46 Nm).

9 - 20 - 84 M4309217
Section 9 Group 20
20.18 Control Valve Section Repair
20.18.1 Lever Operated Spool Section
20.18.1.1 Disassembly Important!

Each valve section body and the valve spool belonging
Note! to that section is a matched set. When more than one
Transition check valves are used in valve sections valve section is being disassembled, the spools should
connected to cylinders, i.e., where the ports are blocked be tagged with the same identifying numbers as the
in neutral. sections to which they belong.
Remove the check valve cap (1), O-ring (2), spring (3), Using a clean rag, grasp the spring end of the valve
and check poppet (4). spool (8), and with a twisting motion, pull the spool out
of the valve section. The retainer plate (9), backup
Remove the two screws (5) securing the back cap (6) to ring (10), and O-ring (11) will come off with the spool.
the valve section (7) and remove the back cap. Discard the O-ring and backup ring.

M4309218 9 - 20 - 85
Group 20 Section 9
20.18.1 Lever Operated Spool Section
20.18.1.1 Disassembly Cont. 20.18.1.2 Assembly
Remove the two retainer screws (12) securing the Clamp the valve spool (8) in a vise fitted with soft jaw
retainer plates (13), the backup ring (14), and the caps.
O-ring (15) to the spool clevis end of the valve section.
Discard the O-ring and backup ring. Apply a small amount of LoctiteTM 262 or equivalent
anaerobic adhesive to the threads of stripper bolt (18).
Important!
Handle the spool very carefully to prevent damage. If the Important!
spool is damaged, the complete valve section must be Follow the adhesive manufacturer’s instructions. Failure
replaced. to clean and prepare the part in accordance with these
instructions can result in faulty assembly.
Note!
Unless the spring (16) or spring guides (17) are to be Assemble the spring (16), spring guides (17), and
replaced, these items should remain installed on the stripper bolt (18) onto the spool (8). Torque the stripper
spool. bolt to 160 to 190 lb in. (18 to 21 Nm). Lightly coat the
spring and guides with high temperature grease to
Important! prevent rusting.
Apply heat to the spool and stripper bolt carefully.
Excessive heat can distort the spool. Apply a light coating of clean hydraulic oil to the valve
spool and place the retaining plate (9), new backup
Place the spool in a vise, fitted with soft jaw caps, and ring (11), and new O-ring (10) on the spool. Carefully
remove the stripper bolt (18). Heat may have to be insert the spool in the valve section body.
applied to break the bond of the anaerobic thread
adhesive used to secure the bolt. Apply LoctiteTM 242 to the threads of the two screws (5)
and install the back cap (6) onto the valve section body.
Remove the spring guides and spring from the spool.
Apply LoctiteTM 242 to the threads of the two screws (12)
Inspect and repair components as outlined in Paragraph and install O-ring (15), backup ring (14), and the two
20.18.2. retainer plates (13) onto the valve section body.
Install the check poppet (4), spring (3), O-ring (2), and
check valve cap (1). Torque the check valve cap
to 80 to 90 lb ft (108 to 122 Nm).

9 - 20 - 86 M4309218
Section 9 Group 20
20.18.2 Pilot Operated Spool Section
20.18.2.1 Disassembly
Note! Remove the two end caps, housing tubes, and

Transition check valves are used in valve sections O-rings (12 and 13). Discard the O-rings.
connected to cylinders, i.e., where the ports are blocked
in neutral. From the clevis end of the valve section, remove the
seal retainer (14) and two O-ring (15 and 16). Discard
Remove the check valve cap (1), O-ring (2), spring (3), the O-rings.
and check poppet (4).
Using a clean rag, grasp the spring end of the valve
Remove the two cap screws (5) securing the end cap (6) spool (17), and with a twisting motion, pull the spool out
and housing tube (7) to the valve section body (8). of the valve section. The seal retainer (18) and two
O-rings (19 and 20) will come off with the spool. Discard
Remove the two cap screws (9) securing the end the O-rings.
cap (10) and housing tube (11) to the other end of the
valve section body.

M4309218 9 - 20 - 87
Group 20 Section 9
20.18.2.1 Disassembly Cont. Clamp the valve spool (17) in a vise fitted with soft jaw
caps.
Important!
Handle the spool very carefully to prevent damage. If the Apply a small amount of LoctiteTM 262 or equivalent
spool is damaged, the complete valve section must be anaerobic adhesive to the threads of stripper bolt (24)
replaced. and assemble the two springs (21 and 22), bushing (25),
washers (23), and stripper bolt onto the spool.
Apply heat to the spool and stripper bolt carefully.
Excessive heat can distort the spool. Torque the stripper bolt to 160 to 190 lb in.
(18 to 21 Nm).
Note!
Unless the springs (21 and 22) or washers (23) are to be Coat the springs (21 and 22) with high temperature
replaced, these items should remain installed on the grease to prevent rusting.
spool.
Apply a light coating of grease to the two
Place the spool (17) in a vise, fitted with soft protective O-rings (19 and 20). Install the O-rings on the
jaw caps, and loosen the stripper bolt (24). Heat may retainer (18), ensuring that the O-rings are correctly
have to be applied to break the bond of the anaerobic positioned, and slide the retainer onto the valve
thread adhesive used on the stripper bolt. spool (17).
Remove the Stripper bolt, two washers (23), Apply a coating of fresh hydraulic oil to the valve spool
springs (21 and 22), and bushing (25) from the spool. and carefully insert the spool in the valve section body.
Inspect and repair components as outlined in Grease the O-ring (12) with a light coat of grease and
Paragraph 20.18.4. install it on the end cap (6).
20.18.2.2 Assembly Install the housing tube (7) onto the retainer (18) and
install the end cap (6) onto the housing tube.
Important!
Follow the adhesive manufacturer’s instructions. Failure Apply LoctiteTM 242 to the threads of the two screws (5)
to clean and prepare the part in accordance with these and secure the end cap to the valve section body.
instructions can result in faulty assembly. Torque the screws to 160 to 190 lb in. (18 to 21 Nm).

9 - 20 - 88 M4309218
Section 9 Group 20
20.18.2.2 Assembly Cont.

Install the housing tube (11) onto the retainer (14) and
Apply a light coating of grease to the two install the end cap (10) onto the housing tube.
O-rings (15 and 16). Install the O-rings on the
retainer (14), ensuring that the O-rings are correctly Apply LoctiteTM 242 to the threads of the two screws (9)
positioned, and slide the retainer onto the clevis end of and install the screws to secure the end cap to the valve
the valve spool. section body. Torque the screws to 160 to 190 lb in.
(18 to 21 Nm).
Grease the O-ring (13) lightly with grease and install it
on the end cap (10).

M4309218 9 - 20 - 89
Group 20 Section 9
20.18.3 Solenoid Operated Spool Section
20.18.3.1 Disassembly Note!

Additional O-rings (9) are used between spool sections.
Note! These O-rings should be removed and discarded also.
Transition check valves are used in valve sections
connected to cylinders, i.e., where the ports are blocked Important!
in neutral. Each valve section body and the valve spool belonging
to that section is a matched set. When more than one
Remove the check valve cap (1), O-ring (2), spring (3), valve section is being disassembled, the spools should
and check poppet (4). be tagged with the same identifying numbers as the
sections to which they belong.
Remove the two cap screws (5) and lock washers (6)
securing the pilot housing (7) to the valve section Remove the pilot piston (10) from the link bolt (11), and
body (8). Remove the pilot housing and discard the two remove the O-rings (12 and 13) and the glydring (14)
O-rings (9). from the piston.

9 - 20 - 90 M4309218
Section 9 Group 20
20.18.3.1 Disassembly Cont.

20.18.3.2 Assembly
Using a clean rag, grasp the spring end of the valve
spool (15), and with a twisting motion, pull the spool out Important!
of the valve section. The retainer (16) and O-rings Follow the adhesive manufacturer’s instructions. Failure
(17 and 18) will be removed with the spool. Discard the to clean and prepare the part in accordance with these
two O-rings. instructions can result in faulty assembly.
Important! Clamp the valve spool (15) in a vise with soft jaw caps.
Handle the spool very carefully to prevent damage. If the
spool is damaged, the complete valve section must be Apply a small amount of LoctiteTM 262 or equivalent
replaced. anaerobic adhesive to the threads of link bolt (11).
Apply heat to the spool and hinge bolt carefully. Assemble the spring (20), two spring guides (19), and
Excessive heat can distort the spool. link bolt (11) onto the spool (15). Torque the link bolt
to 160 to 190 lb in. (18 to 21 Nm).
Place the spool in a vise, fitted with soft jaw caps, and
loosen the link bolt (11). Heat may have to be applied to Coat the spring with high temperature grease to prevent
break the bond of the anaerobic thread adhesive used to rusting.
secure the bolt.
Apply a light coating of grease to two new O-rings
Remove the link bolt, two spring guides (19) and (17 and 18). Install the O-ring (18) on the retainer (16)
spring (20) from the spool. and slide the retainer and O-ring (17) onto the valve
spool (15).
Remove the two screws (21) securing the retainer
plates (22), the backup ring (23), and the O-ring (24) to Apply a coat of fresh hydraulic oil to the valve spool (15)
the valve section. Discard the O-ring and backup ring. and carefully insert the spool in the valve section
body (8).
Inspect and repair components as outlined in Paragraph
20.18.4. Install two new O-rings (12 and 13) and glydring (14) on
the piston (10).

M4309218 9 - 20 - 91
Group 20 Section 9
20.18.3.2 Assembly Cont. Apply LoctiteTM 242 to the threads of the two screws (5).
Install the screws, together with lock washers (6), to
Apply a coat of fresh hydraulic oil to the piston (10) and secure the pilot housing to the valve section body.
connect it to the link bolt (11). Torque the screws to 17 to 19 lb ft. (23 to 25 Nm).
Apply a small amount of grease to two new O-rings (9) Apply LoctiteTM 242 to the threads of the two
and place the O-rings in place on the pilot housing (7). screws (21) and install O-ring (24), backup ring (23), and
the two retainer plates (22) onto the valve section body.
Carefully slide the pilot housing (7) over the piston (10)
and into assembly position with the valve section Install the transition check poppet (4), spring (3),
body (8), making sure that the retainer (16) and O-ring (2), and check valve cap (1). Torque the check
O-ring (18) seat correctly in the pilot housing recess. valve cap to 80 to 90 lb ft (108 to 122 Nm).

9 - 20 - 92 M4309218
Section 9 Group 20
20.18.4 Inspection and Repair valve section body for nicks and burrs that could cause
leakage between the sections. If necessary, lightly stone
Inspect the spool bores, check valve seats, and spools these surfaces to remove any rough spots.
for deep scratches, gouges and excessive wear. If any of
these conditions exist, replace the complete valve Wash and rinse all components thoroughly in clean
section. solvent and blow dry, paying special attention to
numbers and letters marked during disassembly of the
Minor surface damage to the control spool and check valve bank. If any markings are removed by the solvent,
poppet may be carefully polished away using very fine remark the item(s) immediately.
crocus cloth. Examine the machined surfaces of the

M4309218 9 - 20 - 93
Group 20 Section 9
20.19 Relief Valve Repair
Note!
Repair of the system main relief valves and port relief
valves are limited to replacement of external and internal
O-rings.
Important!
Contamination introduced into hydraulic components
can lead to premature equipment failure.
Disassemble and assemble the main relief valve and the

port relief valve as indicated in the illustrations opposite.
Clean and rinse all components in solvent and blow dry

using compressed air.
Typical Relief Valve Remove and discard all O-rings and backup rings and
replace with new seal kits as applicable.
1. O-ring (Body)
2. Backup Ring
3. O-ring (Poppet)
4. O-ring (Valve Housing)
5. O-ring (Pressure Adjustment Screw)

9 - 20 - 94 M4309218
Section 9 Group 20
20.20 Pilot Solenoid Repair

Note!
Repair of the pilot solenoid should be limited to
replacement of O-rings and backup rings or replacement
of the solenoid coil.
Important!
Contamination introduced into hydraulic components
Disassemble and assemble the pilot solenoid from the

solenoid housing as indicated in the illustrations
opposite.
Clean and rinse all components in solvent and blow dry

using compressed air.
Remove and discard all O-rings and backup rings and 1. Solenoid Housing
replace with the items supplied in new seal kit. 2. O-ring
3. Backup Rings (two)
When installing the pilot spool into the solenoid housing, 4. O-ring
torque the spool to 180 lb in. (20 Nm). 5. Backup Rings (two)
6. O-ring
Apply LoctiteTM 242 to the thread on the end of the pilot 7. Pilot Spool
spool prior to installing the nut securing the solenoid coil. 8. Solenoid Coil
Torque the nut to 30 lb in. (3.5 Nm). 9. Nut

M4309218 9 - 20 - 95
Group 20 Section 9
20.21 On-Machine Control Valve Repair
On-machine repair of the main or jib control valves is When removing any relief valve from either control
limited to replacement of the main relief and port relief valve, cap the open valve port immediately to prevent
valves. Refer to Paragraph 20.19 for repair of these contamination of the hydraulic components and to
valves. reduce spill.
On-machine repair of the lower control valve should be When installing a new or repaired main or port relief
limited to repair or replacement of the pilot solenoids, valve, ensure that the relief valve is torqued
refer to Paragraph 20.20 to 80 to 90 lb ft (108 to 122 Nm).
Important! Important!
Cap hydraulic ports, hoses and fittings immediately after When installing a new solenoid coil with different colored
disassembly to prevent components from becoming wires, ensure that the black wire is connected to ground.
contaminated. Contamination introduced into the If installed otherwise, a diode inside the coil may be
hydraulic system can lead to premature equipment damaged.
failure.

9 - 20 - 96 M4309218
Section 9 Group 20
20.22 Joystick Control

The two joystick controls are used to operate all loader
functions with the exception of the swing and stabilizers.
Pilot flow to operate the main, jib, and accessories
control valves are directed and controlled through the
joystick valves.
Strict cleanliness should be exercised when the joystick

valve(s) is removed or installed in the loader and during
repair of the unit(s) on the bench. Whenever a hydraulic
line is disconnected or a component is opened up,
ensure that exposed hose ends or ports are capped
immediately. This not only protects against
contamination but also reduces unwanted hydraulic fluid
spill. When components are disassembled, ensure that
they are completely cleaned and, if required, lubricated
before being assembled.
1. Joystick
2. Seat Armrest
CAUTION 3. Socket Head Cap Screw (Four)
Attach a DO NOT START warning tag to the ignition 4. Electric Wire Connectors (Three Sets)
key or a control lever before undertaking work on 5. Joystick Port Fittings
the hydraulic system. Attempts to run the engine 6. Hydraulic Hoses (Six)
while the hydraulic system is disabled can result in 7. Bottom Armrest Cover
personal injuries and equipment damage. 8. Countersunk Screw (Six)
Tag and disconnect the three sets of wire connectors.

Important!
Cap hydraulic ports, hoses and fittings immediately after Tag and remove the hydraulic hoses from the joystick
disassembly to prevents components from becoming port fittings, one hose at the time. Cap the open hose
contaminated. Contamination introduced into the ends and valve port fittings immediately to prevent
hydraulic system can lead to premature equipment contamination and to reduce hydraulic spill.
failure.
When installing a new or repaired joystick, remove caps
Remove the seat arm rest bottom cover to access the from ports and hoses, one connection at a time, install
hydraulic hoses and electrical wire connections. on the port fittings as tagged and securely tighten the
hoses to prevent leakage.
Important!
The joystick spools are matched to their functions. Connect the electrical wire connectors as tagged and
Always mark assembly position of the joystick in the ensure that all hardware is firmly secured. There is no
armrest and ensure that all hoses are tagged before specific torque requirement for any of the attaching
removing it. hardware.

M4309222
Group 20 Section 9
20.23 Joystick Control Repair
20.23.1 Off-Machine Joystick Repair
1. Joystick Handle* 10. Joint Disc 19. Return Spring

2. Cable Tie 11. Base Plate
3. Boot 12. Valve Housing * Refer to Group 30 for repair of the
4. Cable Tie 13. Socket Head Cap Screw joystick handle and electrical wiring.
5. Jam Nut 14. Plug
6. Jam Nut 15. O-ring ** Spring cartridge for port number
7. Socket Head Cap Screw 16. Push Pin Assembly four is different from the other three
8. Actuator Disc 17. O-ring cartridges.
9. Mounting Ring 18. Spring Cartridge**
Note!
The joystick can be repaired on or off the loader as When assembling the joystick valve, apply lithium
required. If complete disassembly is needed, the joystick grease to items (16, 17, 18, and 19) before installation.
should be removed from the machine before any
disassembly is undertaken. When items (6 through 12) are fully assembled, adjust
the actuator disc (8) such that there is no play between
To ensure correct reassembly, use a quick-drying the actuator disc and the four push pin assemblies (16),
waterproof marker to mark assembly position of items then back off the actuator disc one half turn and tighten
(1, 9, 10, 11 and 12) before disassembling any of the the jam nut (6).
components.

M4309222
Section 9 Group 20
20.23.2 On-Machine Joystick Repair

Repair of the handle and actuator disc assembly, push
pin assemblies, and spring cartridges can be performed
while the joystick is installed in the machine.
Remove the cable tie (1), push the boot (2) out of the
way, and remove the four socket head cap screws (3)
securing the handle and actuator disc assembly (4) to
the base plate.
Note!
If disassembly or removal of the handle and actuator
disc assembly is required, the bottom armrest cover
must be removed and the joystick electrical wires
disconnected, refer to Paragraph 20.22.
The push pin assemblies (5) are separately repairable.

Disassemble and assemble these components as
illustrated below.
When assembling or installing the joystick valve, tighten
When assembling the joystick valve, apply lithium all hardware firmly. There are no specific torque
grease to items (5, 17, and 18) before installation. requirements.

M4309222
Group 20 Section 9
20.23.2 On-Machine Joystick Repair Cont.
5. Push Pin Assembly 14. Spacer

6. Wire Clip 15. Retaining Ring
7. Washer 16. Retaining Ring
8. Spring 17. Spring Cartridge*
9. Pin 18. Return Spring
10. Sleeve
11. O-Ring
12. Seal * Spring cartridge for port number four is different from
13. Retaining Ring the other three cartridges.

M4309222
Section 9 Group 20
20.24 Detent Valve

The detent valve is a solenoid operated valve used in
conjunction with a delimber attachment. The return flow
from the delimber knife function to the tank is opened or
closed by this valve which is controlled by means of one
of the auxiliary implement switches located on either one
of the joysticks or on one of the manual loader control
levers.
CAUTION
Attach a DO NOT START warning tag to the ignition 1. Detent Valve
key or a control lever before undertaking work on 2. Solenoid Wire Connector
the hydraulic system. Attempts to run the engine 3. Cap Screw
while the hydraulic system is disabled can result in 4. Manifold (Not part of the valve)
Note!
To ensure correct reconnection, the solenoid wire
Important! connectors should be tagged before being disconnected.
Cap hydraulic ports, hoses and fittings immediately after
disassembly to prevents components from becoming When installing the detent valve, ensure that the four
contaminated. Contamination introduced into the O-rings in the ports on the back of the valve are in place.
hydraulic system can lead to premature equipment Apply LoctiteTM 242 to the threads of four cap
failure. screws (3) and tighten them to 30 lb in. (3.4 Nm).

M4309224
Group 20 Section 9
20.25 Detent Valve Repair
1. Plunger Tube 8. Finger Nut

2. O-ring 9. O-ring
3. Plunger Pin 10. Solenoid Coil
4. Detent 11. O-ring
5. Roll Pin 12. Valve Body
6. O-ring 13. Name Plate
7. Valve Spool 14. Screw
The detent valve assembly is repairable to the extent Tighten the two plunger tubes (1) firmly into the valve
shown, except the valve body (12) and the name plate body (12). There are no specific torque requirements.
(13) are not separately replaceable. Disassemble and
assemble the components as illustrated. Ensure that the O-rings (9 and 11) are in place when
securing either of the two solenoid coils (10) onto the
Apply Lithium grease or petroleum jelly to all O-rings valve body and plunger tube.
before installation.

M4309224
Section 9 Group 20
20.26 Main Hydraulic Filter Assembly (SPI)
20.26.1 General Information Note!

The diverter head and cover are not separately
The two filter assemblies installed in the hydraulic tank replaceable. If replacement of either of these items is
are provided to remove impurities from the fluid as it required, the complete filter assembly must be replaced.
flows back to tank after use in the system.
The two filter canister tubes (1) are welded in place in
Each filter assembly contains two filter elements which the tank. If replacement of either of these tubes is
must be checked and replaced at regularly scheduled required, the complete tank must be replaced.
intervals as detailed in the Loader Operator’s Manual.
With the exception stated above, disassemble and
20.26.2 Removal/Installation assemble the components in the order illustrated.
Note!
When installing the diverter head, ensure that the word
CAUTION IN, stamped in the housing, faces the tank inlet
Attach a DO NOT START warning tag to the ignition connection.
the hydraulic system. Attempts to run the engine All attaching hardware should be tightened firmly. There
while the hydraulic system is disabled can result in are no specific torque requirements.
1. Filter Canister Tube 6. Center Grommet 11. Seal

2. Cap Screw 7. Cover 12. O-ring
3. O-ring 8. Diverter 13. Service Indicator
4. End Grommet 9. O-ring 14. Lock Washer
5. Filter Element 10. Diverter Head 15. Cap Screw

M4309226
Group 20 Section 9
20.27 Pilot In-line Filter Assembly

The pilot in-line filter is provided as an upstream filter to
remove impurities from the hydraulic fluid before this
fluid enters the joystick control valves.
The filter assembly contains a replaceable filter element

which must be checked and replaced at regularly
scheduled intervals as detailed in the Loader Operator’s
Manual.
CAUTION
1. Plug key or a control lever before undertaking work on
2. O-ring the hydraulic system. Attempts to run the engine
3. O-ring while the hydraulic system is disabled can result in
4. Adapter personal injuries and equipment damage.
5. Filter Head
6. Gasket Seal
7. Filter Canister The in-line filter assembly is repairable to the extent
8. Filter Element shown. Disassemble and assemble the components as
9. Cap Screw illustrated.
10. Flat Washer
Apply LoctiteTM 242 to the threads of cap screws (7)
before installation and tighten the screws firmly. There
are no specific torque requirements.

M4309226
Section 9 Group 20
20.28 Main Hydraulic Tank

The main hydraulic tank serves as reservoir for the
hydraulic fluid. Inside the tank three strainers provide
screening of the flow to the hydraulic pumps. The tank is
also equipped with a temperature and volume gauge as
well as two hydraulic filter assemblies for filtration of the
fluid when it is returned from the system.
This procedure applies to the tanks used on the SPI

machine models as well as the tanks used on the swivel
type machines.
20.28.2 Removal
CAUTION 1. Hydraulic Tank

Attach a DO NOT START warning tag to the ignition 2. Bolt
key or a control lever before undertaking work on 3. Flat Washer
the hydraulic system. Attempts to run the engine 4. Lock Nut
personal injuries and equipment damage. Note!
The tank may be secured to the turntable frame with
four or ten bolts and lock nuts.
CAUTION
The hydraulic tank is heavy! Use appropriate 1. Close the three tank ball valves and drain the fluid.
support, slings, and lifting device to prevent
personal injuries or equipment damage when 2. Tag hydraulic suction and return hoses as necessary
moving the tank and remove them from the tank. Drain the hoses
and cap all hose and port fittings.
Important! 3. Using slings as appropriate, secure the tank to a

Cap all hydraulic ports, hoses, and fittings immediately suitable hoist and remove the hardware securing the
after removal to prevent the components from becoming tank to the turntable frame.
hydraulic system can lead to premature equipment 4. Remove the tank from the turntable frame and place
failure. it on suitable support.

M4309228
Group 20 Section 9
20.28 Main Hydraulic Tank
CAUTION
Observe strict cleanliness when disconnecting and 2. Install the bolts, flat washers and lock nuts to secure
connecting hydraulic components. Contamination the tank to the turntable frame. Torque the lock nuts
induced into the hydraulic system can result in to 30 to 35 lb ft (41 to 47 Nm).
equipment failure.
3. Install the tank drain plug, and all hydraulic suction
and return hoses as tagged.
the hydraulic tank in assembly position on the loader 4. Fill the tank with fluid, refer to Section 4 for fluid
turntable. specifications, and open the tank ball valves.

M4309228
Section 9 Group 20
20.29 Hydraulic Tank Repair
SPI System Main Hydraulic Tank
1. Cap Screw 6. Ball Valve 11. Gasket

2. Flat Washer 7. Adapter 12. Strainer Screen (Small)
3. Strainer Screen 8. Ball Valve (Small) 13. Gasket
4. Drain Plug 9. Screw 14. Cover Plate
5. Adapter 10. Gauge 15. Filler Breather Cap
CAUTION The hydraulic tank is repairable to the extent shown. All

Attach a DO NOT START warning tag to the ignition items mechanically assembled to the tank are
key or a control lever before undertaking work on replaceable with exception of the strainer elbows.
while the hydraulic system is disabled can result in When installing any component with pipe thread, ensure
personal injuries and equipment damage. that LoctiteTM 545 pipe sealant is applied to the thread
before installation.
CAUTION Before installation, apply LoctiteTM 242 to the thread of

The hydraulic tank is normally pressurized, turn the the screws used to secure the gauges and the pressure
tank filler cap approximately 1/4 turn to relieve switch. Tighten all hardware firmly, there are no specific
residual pressure before removing the filler cap or torque requirements.
any other component that can cause sudden
escape of the tank pressure.

M4309228
Group 20 Section 9
20.29 Hydraulic Tank Repair
Swivel System Hydraulic Tank
1. O-ring 10. Filter Element 19. Adapter

2. Breather Cover 11. Elbow 20. Ball Valve
3. Screw 12. Hose 21. Screw
4. Breather Valve Cap and Filter 13. Connector 22. Gauge
5. Screw 14. Cap Screw 23. Gasket
6. Flat Washer 15. Pressure Switch 24. Strainer Screen
7. Filter Cover 16. Drain plug 25. Strainer Screen (Small)
8. Spring 17. Ball Valve (Small)
9. Bypass Valve 18. Adapter

M4309228
Section 9 Group 20
20.30 Lower Hydraulic (SPI) Tank

(SPI) pump. The tank is also equipped with a fluid level
The lower hydraulic tank serves as reservoir for the sight glass as well as a filter assembly for filtration of the
lower (SPI) hydraulic system. The tank is equipped with fluid when it is returned from the (SPI) system
a strainer which provides screening of the flow to the components.
20.30.2 Removal
1. Hydraulic Tank 4. Lock Nut

2. Bolt 5. Frame Stud
3. Flat Washer 6. Tank Bracket
Important!
CAUTION Cap all hydraulic ports, hoses, and fittings immediately
Attach a DO NOT START warning tag to the ignition after disassembly to prevent the components from
key or a control lever before undertaking work on becoming contaminated. Contamination introduced into
the hydraulic system. Attempts to run the engine the hydraulic system can lead to premature equipment
while the hydraulic system is disabled can result in failure.
1. Close the tank ball valve and drain the fluid.

CAUTION
The hydraulic tank is heavy! Use appropriate 2. Remove the hydraulic suction and return hoses from
support, slings, and lifting device to prevent the tank. Drain the hoses and cap all hose and port
personal injuries or equipment damage when fittings.
moving the tank.

M4309230
Group 20 Section 9
20.30 Lower Hydraulic (SPI) Tank
20.30.2 Removal
3. Using slings as appropriate, secure the tank to a
suitable hoist and remove the hardware securing the
tank to the loader base frame.
4. Remove the tank from the loader base frame and the hydraulic tank in assembly position with the
place it on suitable support. loader base frame.
2. Install the bolts, flat washers and lock nuts to secure

20.30.3 Installation the tank to the loader base frame. Torque the lock
nuts to 80 to 90 lb ft (108 to 122 Nm).
CAUTION 3. Install the tank drain plug, and the hydraulic suction
Observe strict cleanliness when disconnecting and and return hoses.
induced into the hydraulic system can result in 4. Fill the tank with fluid, refer to Section 4 for fluid
equipment failure. specifications, and open the tank ball valve.

M4309230
Section 9 Group 20
20.31 Lower Hydraulic (SPI) Tank Repair
1. Hydraulic Tank 10. Cap Screw

2. Cover Plate 11. Bolt
3. Spring 12. Flat Washer
4. Filter Head 13. Tank Cover
5. Filter Element 14. Gasket
6. Screw 15. Gauge
7. Adapter 16. Drain Plug
8. Adapter - 90 Deg. 17. Strainer Screen
9. Filler Cap 18. Adapter
19. Ball Valve
CAUTION When installing any component with pipe thread, ensure

Attach a DO NOT START warning tag to the ignition that LoctiteTM 454 pipe sealant is applied to the thread
key or a control lever before undertaking work on before installation.
while the hydraulic system is disabled can result in Tighten all hardware firmly, there are no specific torque
personal injuries and equipment damage. requirements.
The hydraulic tank is repairable to the extent shown. All

items mechanically assembled to the tank are
replaceable with exception of the strainer elbow.

M4309230
Section 9 Group 20
20.32 Hydraulic Cylinders

The cylinders used to operate the main and jib booms as
well as the stabilizers are all of the same basic design.
The hinge points of the pistons and cylinder barrels vary
with the application of the cylinders; however, the
procedure to repair the various cylinders is
fundamentally the same.
1. Main Boom Cylinder

2. Jib Boom Cylinder
3. Stabilizer Cylinder
Component Number 2881/82/83 9 - 20 - 112

M4309232
Group 20 Section 9
20.32.2 Cylinder Repair
1. Cylinder Barrel 10. O-ring

2. Piston Rod 11. Piston Wear Ring
3. Cylinder Barrel Nut 12. Piston Center Ring
4. Plastic Lock Insert 13. Piston Seal
5. Set Screw 14. Piston
6. Rod Bearing Seal 15. Lock Nut
7. Rod Bearing 16. Retaining Ring
8. Wear Ring 17. Ball Bushing
9. Backup Ring 18. Grease Fitting
The hydraulic cylinders are repairable to the extent Replacement seals and piston rings are generally
shown. All components with the exception of the cylinder supplied as a complete kit.
barrel, the piston and bearing rings, and the seals, are
separately replaceable. When repairing the cylinders ensure that the points
detailed following are performed.
If the cylinder barrel is not repairable, replace the
complete cylinder assembly.
9 - 20 - 113 Component Number 2881/82/83

M4309232
Section 9 Group 20
20.32.2 Cylinder Repair Cont.
Important!
CAUTION Surface damage to the piston, piston bearing, and
The hydraulic cylinder is heavy! Use appropriate cylinder bore can result in premature seal and piston
support, slings, and lifting device to prevent ring failure and subsequent internal or external cylinder
personal injuries or equipment damage when leakage.
working on or moving the cylinder.
Before installing new wear rings, O-rings and seals, use
fine Emery cloth or a Carborundum stone to remove any
Important! nicks and burrs from the wear surfaces and edges of the
Contamination introduced into hydraulic components piston, piston rod, and cylinder barrel.
When installing the piston on the piston rod, apply
Before attempting to remove the cylinder barrel nut (3) hydraulic fluid to the piston rod thread and torque the
from the cylinder, the set screw (5) and the plastic lock lock nut (15) as follows:
insert (4) must be removed.
Lock nut (3.00 in. dia. piston rod) - 2400 lb ft (1980 Nm)
Carefully remove and discard all wear rings, O-rings, Lock nut (3.50 in. dia. piston rod) - 2700 lb ft (1980 Nm)
backup rings, and other seals.
Allowable tolerance: ± 200 lb ft (270 Nm).
Once disassembled, clean and rinse all components in
solvent and blow dry using compressed air. When installing the cylinder barrel nut (3), torque it
to 200 lb ft (270 Nm).
Inspect the disassembled components to determine
reusability. Replace items which are either too damaged Install a new plastic lock insert (4) and set screw (5) to
or deemed excessively worn. lock the cylinder barrel nut in place on the cylinder.
Component Number 2881/82/83 9 - 20 - 114

M4309232
.

Service Manual TJ430

Uploaded by

Copyright:

Available Formats

You might also like

Service Manual TJ430

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual TJ430

Uploaded by

Copyright:

Available Formats

330 / 430 LOG LOADER

S/N – CB1066 – CE1313

Diesel engine exhaust and some of its constituents

The engine exhaust from this product contains

Worldwide Construction and Forestry Division

Model 330 and 430 Loaders

9 Maintenance and Repair

Section 2 - Safety Rules

Section 3 - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . Not Available

4.1 Machine Dimensions - 330 Log Loader . . . . . . . . . . . . . . . . . . . . . . . 4-2

Section 6 - Hydraulic Systems

Section 7 - Electrical Systems

Section 9 - Maintenance and Repair

1.1 Foreword 1-2

Diesel engine exhaust and some of its

1.2 Non-approved Field Product Changes

If any person or organization modifies or contributes in

Options or changes are only officially approved in the

1.3 Warranty Certificate - Timberjack Loaders

Standard Warranty. Compensation under this warranty may be denied if

This warranty may not be changed, altered, or modified

1.4 Items Not Covered By Warranty:

1. Issues resulting from misuse, negligence or accident.

3. Repairs or adjustment by other than Timberjack Inc. or its authorized dealers.

5. Issues resulting from the installation of unauthorized attachments or modifications.

7. Dealer travel or mileage expense.

9. Air, oil and fuel filter elements.

11. Diagnosis time will not be considered warranty labor.

13. Natural wear or defects caused by natural wear.

15. Freight expenses, daily allowances and overtime labor rates.

17. Indirect damages such as loss of earnings, etc.

Other adjustments (but not limited to) such as:

2.1 General 3-2

This machine should not be operated or maintained by

As the operator/maintainer ensure that you become

2.2 Safety Symbol

2.3 Understanding Signal

WARNING denotes a hazard exists which can result in

CAUTION is used in areas where failure to follow listed

2.4 General Safety

Timberjack Inc. policy is to produce products that are

To minimize risks and promote safety at all times, this

Study all the safety messages in this manual and on the

You must be fully trained to operate this equipment.

Do not let an untrained person operate the machine.

Use recommended protective clothing and safety

These safety rules highlight both general and specific

WHEN IT COMES TO SAFETY, NOTHING WILL EVER

2.4 General Safety

Wear a suitable hearing protective device such as

Use the handrails and steps provided when mounting

Face the machine when mounting and dismounting.

Maintain a three-point contact (one foot and two hands

Use a hand line to lift tools or supplies onto the machine.

Inspect the machine daily and when necessary, clean or

Keep floors, steps, and running boards clean and free of

2.4 General Safety

Keep a first aid kit in an easily accessible location on the

Carry no passengers. The vehicle is provided and