SERVICE MANUAL

SKID STEER
COMPACT TRACK LOADER
410
420
420CT

87364090 NA
Replaces 6-78950 NA

CNH AMERICA LLC North American English

700 STATE STREET Part Number 87364090 NA
RACINE, WI 53404 U.S.A. Printed in U.S.A. • Bur
Revised 03-2006
Issued 02-2005
 SERVICE MANUAL
SKID STEER
COMPACT TRACTOR LOADER
410
420
420CT

Bur • Issued 02-2005 (Revised 03-2006)

Printed in U.S.A. • Book/Form Number 87364090 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not
necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer.

REVISION HISTORY
Issue Issue Date Applicable Machines Remarks
First Edition 02-2005 410 and 420 6-78950 NA
Revision 1 03-2006 410, 420, and 420CT 87364090 NA

Any use of editorial or pictorial content is strictly prohibited without express written permission from
CNH America LLC. Carol Stream, IL 60188 U.S.A.
 410/420 SKID STEER AND 420CT COMPACT TRACK LOADER
Service Manual
Bur 87364090
Table of Contents
Publication
Description Section Number
Form Number

General Tab 1
Section Index - General 6-79040
Fluids and Lubricants 1001 6-79031
Standard Torque Specifications 1002 7-52931
Metric Conversion Chart 1003 7-52950

Engines Tab 2
Section Index - Engines 6-79050
Engine and Radiator Removal and Installation 2000 6-79130
For Engine Repair - See Engine Service Manual 6-79550

Fuel Systems Tab 3

Section Index - Fuel Systems 6-79060
For Fuel System Repair - See the Engine Service Manual 6-79550

Electrical Tab 4
Section Index - Electrical 6-79070
Electrical Specifications and Troubleshooting and Schematics 4001 6-79540
Battery 4005 7-51310
Starter and Starter Solenoid 4006 7-53091

Tracks Tab 5

Section Index - Tracks 5-2630

Tracks 5001 5-2610
Drive Sprocket, Idler Wheels, and Rollers 5002 5-2620

Power Train Tab 6

Section Index - Power Train 6-79080
Hydrostatic System Troubleshooting 6001 6-79331
Removal and Installation of Hydrostatic Components 6002 6-79531
Drive Coupling 6003 6-79120
Piston Pump 6004 6-49580
Drive Motors (Eaton) 6005 6-79020
Single Speed Drive Motors 6005 6-79000
Sprocket, Chains, and Axle Assemblies 6007 6-79300

Copyright © 2006 CNH America LLC.

CNH AMERICA LLC. All rights reserved.
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-78991 Issued February, 2005 (Revised March, 2006)
 410/420 SKID STEER AND 420CT COMPACT TRACK LOADER
Service Manual
Bur 87364090
Table of Contents (Continued)
Publication
Description Section Number
Form Number
Wheels and Tires 6011 6-79310

Brakes Tab 7
Section Index - Brakes 6-79090
Removal and Installation of Park Brake Components 7002 6-79571
410 Brakes - Spring Applied - Hydraulic Release
(Refer to Section 6005 - Single Speed Drive Motor)
420 Brakes - Spring Applied - Hydraulic Release 7004 6-79580

Hydraulics Tab 8
Section Index - Hydraulics 6-79100
Hydraulic System Troubleshooting and Schematics 8001 6-79511
Cleaning the Hydraulic System and Hydrostatic System 8002 6-45290
Removal and Installation of Hydraulic Components 8003 6-79520
Gear Pump (Equipment and High Flow) 8004 6-79350
Loader Control Valve 8005 5-2640
Cylinders 8006 6-79360
Flat Faced Couplers 8007 7-54740
Accumulator for Ride Control 8013 6-45550

Mounted Equipment Tab 9

Section Index - Mounted Equipment 6-79110
Pedals and Levers 9001 6-79500
Loader 9002 6-79390
Attachment Coupler 9003 6-79400
ROPS Canopy, Seat, Seat Belts, and Operators Compartment 9004 6-79410
Heater 9006 6-79450

Schematic Set
Hydraulic and Electrical Schematic Foldout In Rear Pocket 6-78971

Bur 6-78991 Revised 3-06 Printed in U.S.A.

 SECTION INDEX

GENERAL

Section Title Section Number

Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003

Copyright © 2005 CNH America LLC

All rights reserved.
CNH AMERICA LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79040 Issued February, 2005
 SECTION INDEX

ENGINE

Section Title Section Number

Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000
For Engine Repair, see the Engine Service Manual

Copyright © 2005 CNH America LLC

All rights reserved.
CNH AMERICA LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79050 Issued February, 2005
 2000
Section
2000

ENGINE AND RADIATOR REMOVAL AND

INSTALLATION

CNH AMERICA LLC Copyright © 2005 CNH America LLC

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79130 February, 2005
2000-2

TABLE OF CONTENTS
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Bur 6-79130 Issued 2-05 Printed in U.S.A.

 2000-3

RADIATOR

Removal STEP 6
NOTE: Photos may be slightly different from the
machine you are repairing. The procedure is the
same.
NOTE: Put caps on all fittings and plugs in all
disconnected hoses.
1
STEP 1
Park the machine on a level surface.

STEP 2
Lift the hood and open the rear access door on the BD05A024
machine. If equipped with a heater, open the heater coolant
valve.
STEP 3
Turn the ignition switch and the master disconnect STEP 7
switch (if equipped) to the OFF position. Install a hose on the drain valve (16) and drain the
radiator (1) into a clean container that holds
STEP 4 approximately 17 litres (4.5 gallons).
Disconnect the negative battery cable from the
battery. STEP 8
If equipped with a heater, close the heater coolant
STEP 5 valve (1).

STEP 9
15
5 3

2
BD04C007

Slowly loosen the radiator cap (15). Disconnect the

overflow hose (5) from the radiator neck. BD05A026

If the machine is equipped with a High Flow Oil

NOTE: Refer to illustration on page 5.
Cooler (1), release the latch (2) on the lower left side
of the oil cooler and swing the oil cooler away from
the radiator. Remove mounting bolts (3) from the
hinge and remove the oil cooler (1) from the radiator
mounting location. Secure the oil cooler away from
the radiator.

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2000-4
STEP 10 STEP 12

5 1

BD04C026 BD04K036

Release the latch on the top of the radiator and tip Move the radiator (1) away from the upper radiator
the radiator out from the mounting location. hose (6) and lower radiator hose (5). Remove the
radiator (1) from the machine.
STEP 11

BD04C007

BD05A025

Loosen the clamps (7) on the lower radiator hose

(10) and clamps (7) on the upper radiator hose (8).
Remove the upper radiator hose (8) and the lower
radiator hose (10) from the radiator (1).
NOTE: Refer to illustration on page 5.

Bur 6-79130 Issued 2-05 Printed in U.S.A.

 2000-5

15

16

BS04M094
1. RADIATOR 9. CLAMP
2. CUSHION 10. LOWER RADIATOR HOSE
3. BOLT 11. SEAL
4. UPPER FRAME ASSEMBLY 12. LOWER FRAME ASSEMBLY
5. COOLANT RECOVERY HOSE 13. NUT
6. COOLANT RECOVERY BOTTLE 14. LOCK WASHER
7. CLAMP 15. RADIATOR CAP
8. UPPER RADIATOR HOSE 16. DRAIN VALVE
410 AND 420 RADIATOR MOUNTING

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2000-6

BS04M095
1. FAN BLADE 7. CAP SCREW
2. SPACER 8. LOCK WASHER
3. LOCK WASHER 9. WASHER
4. CAP SCREW 10. FAN GUARD
5. SHROUD 11. OIL COOLER
6. BOLT
410 AND 420 FAN MOUNTING

Bur 6-79130 Issued 2-05 Printed in U.S.A.

 2000-7

Installation
STEP 13
Installation of the radiator is the reverse procedure of
removal.

STEP 14
After the radiator has been installed, fill the cooling
system. See Section 1001 for the correct coolant
mixture and quantity.

STEP 15
Start and run the engine until it reaches operating
temperature and check for any leaks. Stop the
engine. After the engine has cooled, check the level
of the cooling system and add coolant as required.

Bur 6-79130 Issued 2-05 Printed in U.S.A.

2000-8

ENGINE

Removal STEP 6

STEP 1
Remove the radiator from the machine.

STEP 2
Install plugs and caps on all disconnected hoses and 1 2 3 1
fittings.

STEP 3
Tag all electrical connection for identification during
assembly.

STEP 4 BD05A028

Disconnect the electrical connectors from the rear tail

1 lamps (1) on both sides of the rear access door.
Disconnect the electrical connectors from the rear
worklight (2). Disconnect the electrical connectors
from the backup alarm (3). Remove mounting
hardware from the wiring harness (4) and remove the
harness (4) from the rear access door.

STEP 7

BD05B048

If equipped with a heater, disconnect the heater

hoses (1) from the engine.
1
STEP 5
Lift the rear hood and open the rear access door.

BD05A028

Connect acceptable lifting equipment to the rear

access door. Remove the pivot bolt (1) and lift the
rear access door and remove from the machine.

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 2000-9
STEP 8 STEP 11

BD05A029 BD05B050
1. CYLINDER PIVOT BOLT 1. AIR RESTRICTION INDICATOR SWITCH

Remove the nut from cylinder pivot bolt (1) on the Disconnect the electrical connector for the air
hood end of the cylinder. restriction indicator switch (1).

STEP 9 STEP 12

2 3
1
2

BD05A066 BD05B049

Remove the plastic clip (2) from the hood pivot shaft. Loosen the clamps (1) on the outlet hose (2).
Slide the hood to the left and remove the hood from Remove the outlet hose (2) from the intake and air
the hood pivot shaft on both sides of the machine. filter assembly (3).
Remove the hood from the machine.
NOTE: Torque clamps (1) 3 to 4 Nm (25 to 35
pound-inches) during assembly.
STEP 10
Push the hood to the right hand side of the machine NOTE: Refer to illustration on page 14 and 15.
and remove the left hand side of the hood from the
pivot pin. Remove the hood from the machine. STEP 13
Loosen and remove the mounting bolts and washers
from the air filter housing mounting bracket.

STEP 14
Remove the air cleaner and bracket from the
machine.

Bur 6-79130 Issued 2-05 Printed in U.S.A.

2000-10
STEP 15 STEP 21
Remove the bolts and washers that fasten the front
muffler support rods (5 and 8) and the rear muffler
support rods (14 and 16) to the engine.
NOTE: Torque bolts 23 to 26 Nm (204 to 228
pound-inches) during assembly.

STEP 16
Loosen and remove the bolts and washers that
fasten the muffler to the exhaust manifold.
1
NOTE: Torque the bolts 51 to 61 Nm (38 to 45
pound-feet) during assembly.
Refer to illustration on page 16 and 17. BD05B050
1. ALTERNATOR WIRES

STEP 17 Disconnect the wires from the alternator.

Remove the muffler from the engine.
STEP 22
STEP 18
Remove the cap screws (7), washers (8), fan blade
(1), from the engine. Loosen and remove cap screws
(4), washers (3) and spacer (2) from the engine.
NOTE: Refer to illustration on page 6.

STEP 19
2
1

BD05B049

Remove the throttle linkage (1) from the fuel injection

pump and the linkage (2) to the throttle control lever.
NOTE: Refer to illustration on page 13.

STEP 23
1 2 Disconnect the wire for the engine coolant
temperature switch and the engine oil pressure
BD05B050
switch.
1. STARTER WIRES
2. WIRE HARNESS CLAMP

Disconnect the wires (1) from the starter and from

the alternator (2). Loosen and remove the bolts and
wire harness clamp (2) from the engine.

STEP 20
Loosen and remove the bolts that fastens the ground
wires to the engine. Keep all ground wires together.

Bur 6-79130 Issued 2-05 Printed in U.S.A.

 2000-11
STEP 24 STEP 28

1
2

BD05B049 BD01C188

Disconnect the wire connector for the fuel injection

Disconnect the fuel lines (1) from the engine.
pump solenoid.
Remove the bolts from the clamps (2) and remove
the fuel lines (1) from the engine.
STEP 25
Loosen and remove the bolts that fasten the wire STEP 29
harness to the right side of the machine.

STEP 26
Move the all of the wiring harness out of the way.
1 3
STEP 27

2 1

BD05B049

Loosen and remove the mounting bolts (1) which

fasten the throttle linkage assembly (2) to the engine.
Remove the linkage assembly (2) from the engine.
Loosen and remove the mounting bolts (3) which
fasten the cover (4) to the engine. Remove the cover
BD01C219
(4).
Close the fuel shut off valve.

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2000-12
STEP 30 STEP 34
Use lifting equipment and remove the engine from
the chassis.
NOTE: During assembly apply Molykote GN to the
pump drive joint splines before assembly.
2
Installation

1 STEP 35
Installation of the engine is the reverse procedure of
3 removal.
BD05B049
STEP 36
Loosen and remove the mounting bolts (1) which
fasten the pump drive joint (2) to the flywheel (3). After the engine and radiator have been installed,
Remove the pump drive joint (2) from the flywheel refill the engine cooling system. Refill the engine
(3). crankcase with engine oil. See Section 1001 for the
correct type and quantity of engine coolant and
NOTE: Tighten pump drive joint bolts to a torque of engine oil.
94 to 106 Nm (68 to 78 pound-feet) during assembly.
STEP 37
STEP 31 Start and run the engine at low idle until the engine
reaches operating temperature and check for any
leaks. Stop the engine. After the engine has cooled,
check the level of the coolant in the cooling system.
Add coolant as required. Check the oil level in the
engine crankcase. Add engine oil as required.

BD05B049

Connect acceptable lifting equipment to the engine

lifting eyes at the front and rear of the engine.

STEP 32
Remove the bolt, washers, and nut from the rear
engine mount (2).
NOTE: Torque the bolts 110 to 122 Nm (80 to 90
pound-feet) during assembly.

STEP 33
Remove the bolts, washers, and nut from the front
engine mounts (1).
NOTE: Torque the bolts 110 to 122 Nm (80 to 90
pound-feet) during assembly.
NOTE: Refer to illustration on page 13.

Bur 6-79130 Issued 2-05 Printed in U.S.A.

 2000-13

3 4

3
1

BS04N063
1. FRONT ENGINE MOUNTS 5. PUMP DRIVE JOINT
2. REAR ENGINE MOUNT 6. ENGINE OIL DIPSTICK
3. THROTTLE LEVER 7. ENGINE OIL DIPSTICK MOUNTING BRACKET
4. THROTTLE LINKAGE
ENGINE MOUNTING

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2000-14

BS04M104
1. AIR CLEANER BODY 7. CLAMP
2. PRIMARY FILTER ELEMENT 8. CAP SCREW
3. SECONDARY FILTER ELEMENT 9. WASHER
4. COVER 10. NOT SHOWN
5. DUST VALVE 11. PLUG
6. OUTLET HOSE
410 AIR FILTER ASSEMBLY

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 2000-15

BS04M103
1. AIR CLEANER BODY 7. OUTLET HOSE
2. PRIMARY FILTER ELEMENT 8. CAP SCREW
3. SECONDARY FILTER ELEMENT 9. WASHER
4. COVER 10. CLAMP
5. DUST VALVE 11. PLUG
6. CLAMP
420 AIR FILTER ASSEMBLY

Bur 6-79130 Issued 2-05 Printed in U.S.A.

2000-16

BS04M097
1. MUFFLER 11. SPACER
2. CAP SCREW 12. CAP SCREW
3. LOCK WASHER 13. GASKET
4. NUT 14. SUPPORT ROD
5. SUPPORT ROD 15. CAP SCREW
6. CAP SCREW 16. SUPPORT ROD
7. LOCK WASHER 17. CLAMP
8. SUPPORT ROD 18. EXHAUST TUBE
9. CAP SCREW 19. CAP SCREW
10. SPACER 20. EXHAUST MANIFOLD
410 MUFFLER ASSEMBLY

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 2000-17

BS04M098
1. MUFFLER 10. SPACER
2. CAP SCREW 11. SPACER
3. LOCK WASHER 12. CAP SCREW
4. NUT 13. GASKET
5. SUPPORT ROD 14. SUPPORT ROD
6. CAP SCREW 15. CAP SCREW
7. LOCK WASHER 16. SUPPORT ROD
8. SUPPORT ROD 17. CLAMP
9. CAP SCREW 18. EXHAUST TUBE
420 MUFFLER ASSEMBLY

Bur 6-79130 Issued 2-05 Printed in U.S.A.

2000-18
NOTES

Bur 6-79130 Issued 2-05 Printed in U.S.A.

 SECTION INDEX

FUEL SYSTEM

Section Title Section Number

For Fuel System Repair, See the Engine Service Manual

Copyright © 2005 CNH America LLC

All rights reserved.
CNH AMERICA LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79060 Issued February, 2005
 SECTION INDEX

ELECTRICAL SYSTEM

Section Title Section Number

Electrical Specifications and Troubleshooting and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4005
Starter and Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4006

Copyright © 2005 CNH America LLC

All rights reserved.
CNH AMERICA LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79070 Issued February, 2005
 4001
Section
4001

ELECTRICAL SYSTEM SPECIFICATIONS,

TROUBLESHOOTING, AND SCHEMATICS

Copyright © 2005 CNH America LLC.

CNH AMERICA LLC. All rights reserved.
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79540 Issued February, 2005
4001-2

TABLE OF CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Circuit Diagram Legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ELECTRICAL SCHEMATIC FRAME 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRICAL SCHEMATIC FRAME 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ELECTRICAL SCHEMATIC FRAME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ELECTRICAL SCHEMATIC FRAME 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ELECTRICAL SCHEMATIC FRAME 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ELECTRICAL SCHEMATIC FRAME 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ELECTRICAL SCHEMATIC FRAME 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ELECTRICAL SCHEMATIC FRAME 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ELECTRICAL SCHEMATIC FRAME 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ELECTRICAL SCHEMATIC FRAME 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ELECTRICAL SCHEMATIC FRAME 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ELECTRICAL SCHEMATIC FRAME 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
ELECTRICAL SCHEMATIC FRAME 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
ELECTRICAL SCHEMATIC FRAME 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
ELECTRICAL SCHEMATIC FRAME 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ELECTRICAL SCHEMATIC FRAME 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ELECTRICAL SCHEMATIC FRAME 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
ELECTRICAL SCHEMATIC FRAME 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
ELECTRICAL SCHEMATIC FRAME 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ELECTRICAL SCHEMATIC FRAME 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ELECTRICAL SCHEMATIC FRAME 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ELECTRICAL SCHEMATIC FRAME 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ELECTRICAL SCHEMATIC FRAME 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ELECTRICAL SCHEMATIC FRAME 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
ELECTRICAL SCHEMATIC FRAME 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
ELECTRICAL SCHEMATIC FRAME 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
CONNECTORS
SCHEMATIC FRAME 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connector 4 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connector 7 Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connector 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connector 8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Connector 9 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Connector 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Connector 52A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
CONNECTORS
SCHEMATIC FRAME 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connector 14 Main Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connector 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connector 64 Options Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
CONNECTORS
SCHEMATIC FRAME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connector 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
CONNECTORS
SCHEMATIC FRAME 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connector 8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connector 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connector 18 Interlock Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Connector 23 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Connector 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Connector 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Bur 6-79540 Issued 2-05 Printed in U.S.A.
 4001-3
Connector 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connector 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connector 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connector 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connector 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connector 127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connector 127A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
CONNECTORS
SCHEMATIC FRAME 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Connector 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Connector 8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Connector 23 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Connector 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Connector 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Connector 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Connector 52A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
CONNECTORS
SCHEMATIC FRAME 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connector 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connector 8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connector 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connector 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connector 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Connector 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Connector 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Connector 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
CONNECTORS
SCHEMATIC FRAME 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Connector 39 (Grey) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
CONNECTORS
SCHEMATIC FRAME 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Connector 50A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Connector 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Connector 51A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connector 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connector 65A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connector 112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connector 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Connector 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Connector 140A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Connector 141 Wiper/Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
CONNECTORS
SCHEMATIC FRAME 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connector 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connector 70A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connector 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connector 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connector 81B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connector 120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connector 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connector 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connector 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connector 124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CONNECTORS
SCHEMATIC FRAME 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connector 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CONNECTORS

Bur 6-79540 Issued 2-05 Printed in U.S.A.

4001-4
SCHEMATIC FRAME 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connector 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connector 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
CONNECTORS
SCHEMATIC FRAME 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Connector 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Connector 71A (Euro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
CONNECTORS
SCHEMATIC FRAME 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Connector 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Connector 70A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connector 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connector 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connector 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connector 115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Connector 115A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
CONNECTORS
SCHEMATIC FRAME 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Connector 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Connector 117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Connector 117A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Connector 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Connector 171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Connector 174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connector 175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connector 176 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
CONNECTORS
SCHEMATIC FRAME 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connector 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connector 66A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Connector 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Connector 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
CONNECTORS
SCHEMATIC FRAME 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Connector 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Connector 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Connector 138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Connector 138A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Connector 150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Connector 150A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
CONNECTORS
SCHEMATIC FRAME 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Connector 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Connector 127B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Connector 127C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Connector 128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Connector 129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Connector 130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
CONNECTORS
SCHEMATIC FRAME 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Connector 66B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Connector 66C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Connector 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Connector 275 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Connector 276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
CONNECTORS
SCHEMATIC FRAME 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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Connector 86B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Connector 226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Connector 227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Connector 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Connector 229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Connector 230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
CONNECTORS
SCHEMATIC FRAME 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Connector 50C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Connector 50D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Connector 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
CONNECTORS
SCHEMATIC FRAME 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Connector 71B (Euro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Connector 71C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Connector 190 (Euro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
CONNECTORS
SCHEMATIC FRAME 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connector 79B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connector 79C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connector 79D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connector 85A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connector 85D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Connector 123B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Connector 123C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Connector 123D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
CONNECTORS
SCHEMATIC FRAME 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Connector 39F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Connector 39G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Connector 39H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Connector 49H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Connector 77H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Electronic Instrument CONSOLE (EIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Electronic Instrument PANEL (EIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Electronic Instrument Cluster (EIC) Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Special Feature Choices: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Detailed Description of Setup Items: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
TROUBLESHOOTING
ELECTRONIC INSTRUMENT CLUSTER (EIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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GENERAL INFORMATION
Wire Identification
625A W 3.0
Circuit Diagram Legends
Wire Size
Earth connection terminal
Wire Color
Wire Number

WIRE SIZE IN MM WIRE SIZE IN STANDARD

Intersection of two wires with connecting points 0.8 MM 2.0 MM 18 - GAUGE 14 - GAUGE
1.0 MM 5.0 MM 16 - GAUGE 10 - GAUGE

Fuses
Intersection of two wires without connecting points
Options Primary
Fuse Block Fuse Block
Diode 9 13
5 1
Indicates frame continued on 6 2 14
10
7 3
9
8 4
11 15 17
Indicates component number

6
12 16
Bulb or lamp

Color Abbreviations
87457332
1. LIGHTS
B---Black LG--Light Green T---Tan 2. WIPER (IF EQUIPPED)
BR-Brown O---Orange V---Violet 3. INTERLOCK/INSTRUMENT CLUSTER
G---Gray P---Pink W---White 4. HORN/BACKUP ALARM
LB-Light Blue R---Red Y---Yellow 5. FRONT ELECTRIC/ACCESSORY
6. HEATER/AIR CONDITIONING (IF EQUIPPED)
7. HAZARD/HIGH FLOW (IF EQUIPPED)
8. HYDRAULIC COUPLER/BEACON (IF EQUIPPED)
9. INTERLOCK RELAY
10. MAIN POWER RELAY
11. STARTER RELAY
12. N/A
13. ACCESSORY POWER RELAY
14. AUXILIARY INTERLOCK / FUEL SHUTOFF RELAY
15. AUXILIARY INTERLOCK / STARTER RELAY
16. WORK LIGHT / ROAD LIGHT RELAY
17. HAZARD FLASHER

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TROUBLESHOOTING
1 Battery
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the
electrical system. Use a multimeter for the following tests.

2 Alternator
Check Points Reading Possible Cause of Bad Readings

Terminal for wire 120A to ground 12 volts Check wire 120A between the alternator and the starter battery terminal.
Also check the starter (3).

NOTE: Turn the ignition switch to the RUN position.

Terminal for wire 121A to ground Approximately Check the circuit from the alternator through the 50 ohm resistor to the fuse
1.1 volts block (11) Frame 2. Also check the 50 ohm resistor and the fuse block (11)
Frame 2.

NOTE: Start the engine.

Terminal for wire 124A to ground Voltage varies Bad alternator.

with engine RPM

3 Starter Motor and Solenoid

Check Points Reading Possible Cause of Bad Readings

Battery terminal of starter to ground 12 volts Check the battery cable to the positive post of the battery.

NOTE: Have another person hold the ignition switch to the START position.

Terminal for wire 625D to ground 12 volts Check the circuit between the starter and starting relay. Also check the
starting relay (5).

NOTE: If the readings are good, the starter motor and solenoid should be bench tested.

5 Starting Relay
Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178A to ground Continuity Bad ground circuit.

Terminal for wire 170A to ground 12 volts Check the circuit between the starter relay and the 40 ampere circuit
breaker. Also check the 40 ampere circuit breaker and the buss bar.

NOTE: Make sure all electrical switches except the ignition switch are in the OFF position. Have another person hold the ignition switch
in the START position.

Terminal for wire 622D to ground 12 volts Check the circuit between the starter relay and the ignition switch (7). Also
check the ignition switch (7).

Terminal for wire 625A to ground 12 volts Bad starter relay.

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7 Ignition Switch
Check Points Reading Possible Cause of Bad Readings

Terminal for wire 130D to ground 12 volts Check the circuit between the ignition switch and the 15 amp circuit
breaker. Also check the 15 ampere circuit breaker.

NOTE: Remove the Instrument Cluster from the right side A post. Uncouple the 26 pin connector from the Instrument Cluster. Uncouple
the 4 pin connector from the Key Switch. Turn the ignition switch to the ON position.

Check between the BAT terminal and the Continuity Bad ignition switch.
IGN terminal of the ignition switch

Check between the BAT terminal and the Continuity Bad ignition switch.
ACC terminal of the ignition switch

NOTE: Have another person hold the ignition switch to the START position.

Check between the BAT terminal and the Continuity Bad ignition switch.
START terminal of the ignition switch

Check between the BAT terminal and the Continuity Bad ignition switch.
IGN terminal of the ignition switch

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1. BATTERY 5. STARTER RELAY

2. ALTERNATOR 6. RESISTOR (50 OHM)
3. STARTER AND SOLENOID 7. IGNITION SWITCH
4. CIRCUIT BREAKERS
ELECTRICAL SCHEMATIC FRAME 1

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8 Main Power Relay
Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178B to ground Continuity Bad ground circuit.

Terminal for wire 190A to ground 12 volts Check the circuit between the main power relay and the 40 ampere circuit
breaker in the buss bar. Also check the 40 ampere circuit breaker and the
buss bar.

NOTE: Turn the ignition switch to the RUN position.

Terminal for wire 131C to ground 12 volts Check the circuit between the main power relay and the ignition switch (7)
Frame 1. Also check the ignition switch (7) Frame 1. Also check the reverse
polarity diode (10).

Terminal for wire 136A to ground 12 volts Bad main power relay.

Terminal for wire 137F to ground 12 volts Check the circuit between the main fuse block and the main power relay.
Also check the main power relay.

9 Options Power Relay

Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178AH to ground Continuity Bad ground circuit.

Terminal for wire 180A to ground 12 volts Check the circuit between the options power relay and the circuit breaker.
Also check the circuit breaker.

NOTE: Turn the ignition switch to the RUN position.

Terminal for wire 137D to ground 12 volts Check the circuit between the options power relay and the ignition switch
(7) Frame 1 “ACC” position. Also check the ignition switch (7) Frame 1.

Terminal for wire 138A to ground 12 volts Bad options power relay.

11 Primary Fuse Block

Check Points Reading Possible Cause of Bad Readings

Terminal for wire 136A to ground 12 volts Bad main power relay (8).

NOTE: Turn the ignition switch to the RUN position.

Terminal for wire 137F to ground 12 volts Check the circuit between the fuse block and the main power relay (8). Also
check the main power relay (8).

Terminal for wire 780A to ground 12 volts Bad 20 ampere fuse or missing fuse.

Terminal for wire 830A and 610A to ground 12 volts Bad 25 ampere fuse or missing fuse.

Terminal for wires 890A and 895A to 12 volts Bad 10 ampere fuse or missing fuse.
ground

Terminal for wire 200H to ground 12 Volts Check the circuit between the fuse block and the ignition switch (5). Also
check the ignition switch (5).

Terminal for wire 300A to ground 12 volts Bad 15 ampere fuse or missing fuse.

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12 Options Fuse Block
Check Points Reading Possible Cause of Bad Readings

NOTE: Turn the ignition switch to the RUN position.

Terminal for wire 138A to ground 12 volts Check the circuit between the options fuse block and the primary fuse block
(11). Also check the primary fuse block (11).

Terminal for wires 817A and 817F to 12 volts Bad 15 ampere fuse or missing fuse.
ground

Terminal for wire 820A to ground 12 volts Bad 10 ampere fuse or missing fuse.

Terminal for wires 751D and 751F to 12 volts Bad 10 ampere fuse or missing fuse.
ground

Terminal for wires 540B and 540C to 12 volts Bad 10 ampere fuse or missing fuse.
ground

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8. MAIN POWER RELAY 11. PRIMARY FUSE BLOCK

9. OPTIONS POWER RELAY 12. OPTIONS FUSE BLOCK
10. DIODE (REVERSE POLARITY)
ELECTRICAL SCHEMATIC FRAME 2

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15 Fuel Hold In Solenoid
Check Points Reading Possible Cause of Bad Readings

Between the housing of the solenoid and Continuity Bad ground connection.
ground

NOTE: Turn the key switch to the RUN position. Have someone sit in the operators seat with the seat bar in the down position.

Terminal for wire IVC3 to ground 12 volts Check the circuit between the fuel hold in solenoid and the interlock relay
(18) Frame 5. Also check the interlock relay (18) Frame 5.

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13. NOT USED 15. FUEL HOLD-IN SOLENOID

14. FUEL PUMP
ELECTRICAL SCHEMATIC FRAME 3

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16. COIL 17. GLOW PLUGS

ELECTRICAL SCHEMATIC FRAME 4

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18 Interlock Relay
Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178E to ground Continuity Bad ground circuit.

NOTE: Turn the key switch to the RUN position. Have someone sit in the operators seat with the seat bar in the down position.

Terminal for wire 300B to ground 12 volts Check the circuit between the interlock relay and the 15 ampere fuse in the
primary fuse block (11) Frame 2. Also check the 15 ampere fuse and the
fuse block (11) Frame 2.

Terminal for wire 303D to ground 12 volts Check the circuit between the interlock relay and the seat bar switch. Also
check the seat bar switch. Also check the instrument cluster.

Terminal for wire 311B to ground 12 volts Bad interlock relay.

19 Seat Switch
Check Points Reading Possible Cause of Bad Readings

NOTE: Remove the Instrument Cluster from the right side A post. Uncouple the 26 pin connector from the Instrument Cluster. Sit in the
operators seat.

Pin 12 on the 26 pin wiring harness connec- Approximately Check the 15 ampere fuse in the primary fuse block (11) Frame 2. Check
tor to ground 12 volts the seat switch. Check fro wiring continuity from the pin 12 pin of the instru-
ment cluster connector to the 15 amp fuse. Also check the 30 pin connector
cavity C1.

20 Seat Bar Switch

Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178E to ground Continuity Bad ground connection through wire.

NOTE: Remove the Instrument Cluster from the right side A post. Have another person sit in the operators seat and move the seat bar
down to the operating position. Turn the ignition switch to the RUN position. Visually observe the flashing LED next to the loader enable
button. Have another person push and release the button.

Terminal 12 of the instrument cluster con- Approximately Ensure continuity from the 15 amp fuse in the buss bar, through the seat
nector. 12 volts switch to the instrument cluster connector pin 12.

Terminal for wire 311B at the interlock relay Approximately Check the 15 amp fuse in the primary fuse block (11) Frame 2.
to ground. 12 volts
Terminal for wire 303D at the coil of the
interlock relay (terminal 86) to ground.
Instrument cluster 26 pin connector pin 14.

Loader valve solenoid wire 311F. Approximately Check the circuit from the loader valve solenoids to wire 3311B at the relay
12 volts contact to ground.
Check the interlock relay. Check the circuit fro wire 300B from the interlock
relay terminal 30 to the 15 amp fuse in the primary fuse block (11) Frame 2.

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22 and 23 Loader Valve Solenoids
Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178K to ground Continuity Bad ground circuit.

Terminal for wire 178BD to ground Continuity Bad ground circuit.

NOTE: Turn the ignition switch to the RUN position. Have someone sit in the operators seat with the seat bar in the down position.
Ensure that the cab door (if installed) is closed and latched.

Terminal for wire 311G to ground 12 volts Check the circuit between the loader valve solenoid and the cab door
switch (48) Frame 10. Also check the cab door switch (48) Frame 10
NOTE: If the front door option is not installed, check the diode installed in
the front door interlock connector in the cab harness.

Terminal for wire 311H to ground 12 volts Check the circuit between the loader valve solenoid and splice 14.

NOTE: If the readings are ok, check with a screwdriver to see whether the solenoid magnetizes when energized. If not, replace the sole-
noid. If the solenoid magnetizes, the problem may be in the hydraulic system.

24 Brake Release Solenoid

Check Points Reading Possible Cause of Bad Readings

NOTE: Disconnect the connector from the brake solenoid. Have someone sit in the seat with the seat bar in the down position. Turn the
ignition switch to the RUN position.

Instrument cluster pin 8 or terminal for wire Approximately 0 Bad instrument cluster output.
258B to ground. volts

Terminal for wire 178CJ to ground Continuity Bad solenoid ground.

Push and release the park brake button on Approximately Bad instrument cluster output.
the instrument cluster. 12 volts
Instrument cluster pin 8 or terminal for wire
258B to ground.

Reconnect the connector to the brake sole- Approximately Check the circuit for wire 258B to the instrument cluster.
noid. 12 volts
Terminal for wire 258B at the brake sole-
noid to ground

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18. INTERLOCK RELAY 22. LOADER VALVE SOLENOID

19. SEAT SWITCH 23. LOADER VALVE SOLENOID
20. SEAT BAR SWITCH 24. BRAKE RELEASE/TANDEM PUMP NEUTRAL OVERRRIDE
21. NOT USED SOLENOID
25. OPTION NOT AVAILABLE 410 AND 420
ELECTRICAL SCHEMATIC FRAME 5

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Instrument Cluster
Check Points Reading Possible Cause of Bad Readings

NOTE: See Troubleshooting Electronic Instrument Cluster (EIC) in this Section.

27 Hydraulic Filter Pressure Switch

Check Points Reading Possible Cause of Bad Readings

Check between the housing of the Continuity Bad ground connection between the hydraulic filter pressure switch and
hydraulic filter pressure switch and the fil- the filter housing.
ter housing.

Check between switch housing and Continuity Bad ground connection between filter housing and frame.
engine ground.

NOTE: Turn the ignition switch to the RUN position.

Terminal for wire 261A to ground Approximately Check the circuit between the hydraulic filter pressure switch and the
12 volts instrument cluster. Also check the instrument cluster.
If the readings are good, replace the hydraulic filter pressure switch.

28 Hydraulic Oil Temperature Sender

Check Points Reading Possible Cause of Bad Readings

Disconnect the connector from the For tempera- Temperature of oil outside of range indicated.
hydraulic oil temperature sender and use tures greater Bad sender.
a voltmeter set to read resistance. than 60o F the
Measure the resistance from the sender sender resis-
terminal to the machine frame. tance should
measure
between 4300
ohms 60o F
and 180 ohms
212o F.

Reconnect the connector to the hydraulic For tempera- Temperature of oil outside of range indicated.
oil temperature sender. tures greater Bad sender.
Remove the instrument cluster and dis- than 60o F the bad wiring to the sender.
connect the 26 pin connector from the sender resis-
instrument cluster. tance should
Measure the resistance from terminal 2 to measure
terminal 20 of the 26 pin connector in the between 4300
wiring harness. ohms 60o F
and 180 ohms
212o F.

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29 Engine Coolant Temperature Sender
Check Points Reading Possible Cause of Bad Readings

Disconnect the connector from the For tempera- Temperature of oil outside of range indicated.
engine coolant temperature sender and tures greater Bad sender.
use a voltmeter set to read resistance. than 60o F the
Measure the resistance from the sender sender resis-
terminal to the machine frame. tance should
measure
between 4300
ohms 60o F
and 180 ohms
212o F.

Reconnect the connector from the engine For tempera- Temperature of oil outside of range indicated.
coolant temperature sender. tures greater Bad sender.
Remove the instrument cluster and dis- than 60o F the Bad wiring to sender.
connect the 26 pin connector from the sender resis-
instrument cluster. tance should
Measure the resistance from terminal 25 measure
to terminal 20 of the 26 pin connector in between 4300
the wiring harness. ohms 60o F
and 180 ohms
212o F.

30 Air Filter Restriction Switch

Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178G to ground. Continuity Bad ground circuit.

NOTE: Turn the ignition switch to the RUN position.

Terminal for wire 266C to ground Approximately Check the circuit between the air filter restriction switch and the instru-
12 volts ment cluster connector pin 16.
Also check the instrument cluster.

Remove the switch from the air filter and Continuity Bad switch.
apply 64m bar vacuum to the port.

31 Fuel Level Sender

Check Points Reading Possible Cause of Bad Readings

NOTE: Check the level of fuel in the fuel tank.

Check between the housing of the fuel Continuity Bad ground connection inside the fuel level sender.
level sender and the engine block.

NOTE: Disconnect the connector for wire 234A from the fuel sender.

Terminal for wire 234A to ground Approximately Check for continuity between the fuel level sender and the instrument
12 volts cluster pin 1. Also check the instrument.
When the tank is full the resistance should be 80 ohms or less.
If the tank is empty, the resistance should be 180 ohms or greater. If the
ohmmeter readings are not correct, replace the fuel level sender.

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32 Engine Oil Pressure Switch
Check Points Reading Possible Cause of Bad Readings

Check between the housing of the engine Continuity Bad sensor internal ground connection between the engine oil pressure
oil pressure switch and the engine block. switch and the engine block.

NOTE: Turn the ignition switch to the RUN position. Disconnect the connector from the engine oil pressure switch.

Terminal for wire 255C to ground Approximately Check the circuit between the engine oil pressure switch and the instru-
12 volts ment cluster. Also check the instrument cluster.

NOTE: Connect the connector to the engine oil pressure switch. Turn the ignition switch to the RUN position. Engine should not be
running.

Terminal for wire 255C to ground Approximately Bad engine oil pressure switch.
0 volts

NOTE: Start and run the engine at low idle.

Terminal for wire 255C to ground Approximately Engine oil pressure less than 70 kPa (10 psi).
12 volts

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26. NOT USED 30. AIR FILTER RESTRICTION SWITCH

27. HYDRAULIC FILTER PRESSURE SWITCH 31. FUEL SENDER
28. HYDRAULIC OIL TEMPERATURE SENDER 32. ENGINE OIL PRESSURE SWITCH
29. ENGINE COOLANT TEMPERATURE SENDER 33. CHARGE PRESSURE SWITCH
ELECTRICAL SCHEMATIC FRAME 6

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Work/Road Light Switch
Check Points Reading Possible Cause of Bad Readings

NOTE: See Troubleshooting Electronic Instrument Cluster (EIC) in this Section.

37 Left Front Work Lamp

Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178X to ground Continuity Bad ground circuit.

Bulb Good Bad bulb.

NOTE: Turn the ignition switch to the RUN position. Push and release the work/road light switch i on the instrument cluster.

Terminal for wire 783F to ground 12 volts Check the circuit between the left front work lamp and the work/road light
switch. Also check the work/road light switch.

38 Right Front Work Lamp

Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178R to ground Continuity Bad ground circuit.

Bulb Good Bad bulb.

NOTE: Turn the ignition switch to the RUN position. Push and release the work/road light switch i on the instrument cluster.

Terminal for wire 783G to ground 12 volts Check the circuit between the right front work lamp and the work/road
light switch. Also check the work/road light switch.

39 Rear Work Lamp

Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178F to ground Continuity Bad ground circuit.

Bulb Good Bad bulb.

NOTE: Turn the ignition switch to the RUN position. Push and release the work lamp button on the instrument cluster.

Terminal for wire 784A to ground 12 volts Check the circuit between the rear work lamp and light relay No. 2. Also
check light relay No. 1.
Also check the instrument cluster.

40 Left Rear Indicator Lamp

Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178L to ground Approximately Bad ground circuit

12 volts

Bulb Good Bad bulb.

NOTE: Turn the ignition switch to the RUN position. Push and release the light button on the instrument cluster.

Terminal for wire 706B to ground 12 volts Check the circuit between the rear positional lamp lamps and the light
relay No. 2.
Also check the light relay No. 2.

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41 Right Rear Indicator Lamp
Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178W to ground Approximately Bad ground circuit

12 volts

Bulb Good Bad bulb.

NOTE: Turn the ignition switch to the RUN position. Push and release the light button on the instrument cluster.

Terminal for wire 706C to ground 12 volts Check the circuit between the rear positional lamp lamps and the light
relay No. 2.
Also check the light relay No. 2.

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34. DIODE 38. RIGHT FRONT WORKLIGHT

35. LIGHT RELAY NO. 1 39. REAR WORKLIGHT
36. LIGHT RELAY NO.2 40. LEFT REAR INDICATOR LAMP
37. LEFT FRONT WORKLIGHT 41. RIGHT REAR INDICATOR LAMP
ELECTRICAL SCHEMATIC FRAME 7

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44 Horn
Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178M to ground Continuity Bad ground circuit.

NOTE: Turn the ignition switch to the RUN position. Have another person hold down the horn switch.

Terminal for wire 892A to ground 12 volts Check the circuit between the horn and the horn switch (92) Frame
25. Also check the horn switch (92) Frame 25.

NOTE: If the readings are good and the horn does not work, replace the horn.

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44. HORN
ELECTRICAL SCHEMATIC FRAME 8

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45 Backup Alarm Switch (Left)
Check Points Reading Possible Cause of Bad Readings

NOTE: Place the Skid Steer Loader on acceptable supports so that all four wheels are off the ground. Disconnect the electrical con-
nector from backup alarm switch (Left). Turn the ignition switch to the RUN position.

Check between the switch terminal for Approximately Check the circuit between backup alarm switch terminal 42 and the
wire 895A to ground 12 volts 10 ampere fuse in the primary fuse block (11) Frame 2. Also check
the 10 ampere fuse and the primary fuse block (11) Frame 2.

Check between opposite ends of wire Continuity Bad circuit between backup alarm switches.
895B.

Check between the terminals of each Open Bad backup alarm switch (Left).
individual backup alarm switch.

Start the engine and run at low idle. Continuity Bad backup alarm switch (Left).
Have another person move the control
levers to the REVERSE position.
Check between the terminals of each
untidily backup alarm switch.

46 Backup Alarm Switch (Right)

Check Points Reading Possible Cause of Bad Readings

NOTE: Place the Skid Steer Loader on acceptable supports so that all four wheels are off the ground. Disconnect the electrical con-
nector from backup alarm switch (Right). Turn the ignition switch to the RUN position.

Check between the switch terminal for Approximately Check the circuit between backup alarm switch terminal 42 and the
wire 895A to ground 12 volts 10 ampere fuse in the primary fuse block (11) Frame 2. Also check
the 10 ampere fuse and the primary fuse block (11) Frame 2.

Check between opposite ends of wire Continuity Bad circuit between backup alarm switches.
895B.

Check between the terminals of each Open Bad backup alarm switch (Right).
individual backup alarm switch.

Start the engine and run at low idle. Continuity Bad backup alarm switch (Right).
Have another person move the control
levers to the REVERSE position.
Check between the terminals of each
individual backup alarm switch.

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47 Backup Alarm
Check Points Reading Possible Cause of Bad Readings

NOTE: Place the Skid Steer Loader on acceptable supports so that all four wheels are off the ground. Disconnect the electrical con-
nector from backup alarm switch (Left). Turn the ignition switch to the RUN position. Have another person move the control handles to
the REVERSE position.

Terminal for wire 178N to ground. Continuity Bad ground circuit.

Check between the backup alarm and the Approximately Bad backup alarm.
terminal for wire 897A to ground 12 volts

NOTE: If the readings are good but the backup alarm doesn’t sound, replace the backup alarm.

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45. BACKUP ALARM SWITCH (LEFT) 47. BACKUP ALARM

46. BACKUP ALARM SWITCH (RIGHT)
ELECTRICAL SCHEMATIC FRAME 9

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48 Cab Door Switch
Check Points Reading Possible Cause of Bad Readings

NOTE: Disconnect the connector from the cab door switch. Cab door should be open.

Between the terminal for the white wire and Open Bad cab door switch.
the terminal for the black wire for the cab
door switch.

NOTE: Close and latch the cab door.

Between the terminal for the white wire and Continuity Bad cab door switch.
the terminal for the black wire for the cab
door switch.

NOTE: Have someone sit in the seat with the seat bar in the down position. Turn the ignition switch to the RUN position.

Terminal for wire 313G to ground 12 volts Check the circuit between the cab door switch and the loader lock out relay
(84) Frame 22. Also check the loader lock out relay (84) Frame 22.

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48. CAB DOOR SWITCH 48A. WIPER/WASHER SWITCH

ELECTRICAL SCHEMATIC FRAME 10

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49 High Flow Switch
Check Points Reading Possible Cause of Bad Readings

NOTE: Have someone sit in the seat with the seat bar in the down position. Turn the ignition switch to the RUN position.

Terminal for wire 751E to ground 12 volts Check the circuit between the high flow switch and the 10 amp fuse in the
options fuse block (12) Frame 2.

NOTE: Have another person hold the high flow switch in the FWD position.

Terminal for wire 535A to ground 12 volts Bad high flow switch or internal handle wiring. Disassemble handle and
check the circuit between the high flow switch and the connector. If OK,
replace the high flow switch.

52 Forward High Flow Solenoid

Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178DC to ground Continuity Bad ground circuit.

NOTE: Have someone sit in the seat with the seat bar in the down position. Turn the ignition switch to the RUN position. Have the other
person hold the high flow switch in the FWD position.

Terminal for wire 545B to ground 12 volts Check the circuit between the forward high flow solenoid and the high flow
switch (49). Also check the high flow switch (49).

NOTE: If the readings are ok, check with a screwdriver to see whether the solenoid magnetizes when energized. If not, replace the sole-
noid. If the solenoid magnetizes, the problem may be in the hydraulic system.

53 Reverse High Flow Solenoid

Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178DD to ground Continuity Bad ground circuit.

NOTE: Have someone sit in the seat with the seat bar in the down position. Turn the ignition switch to the RUN position. Have the other
person hold the high flow switch in the REV position.

Terminal for wire 546CB to ground 12 volts Check the circuit between the reverse high flow solenoid and the high flow
switch (49). Also check the high flow switch (49).

NOTE: If the readings are ok, check with a screwdriver to see whether the solenoid magnetizes when energized. If not, replace the sole-
noid. If the solenoid magnetizes, the problem may be in the hydraulic system.

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49. ELECTRO-HYDRAULIC HIGH FLOW SWITCH 52. FORWARD SOLENOID

50. DIODE 53. REVERSE SOLENOID
51. COMBINATION SOLENOID
ELECTRICAL SCHEMATIC FRAME 11

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54 Ride Control Solenoid
Check Points Reading Possible Cause of Bad Readings

Check between the housing of the ride Continuity Bad ground connection.
control solenoid and ground

NOTE: Turn the ignition switch to the RUN position. Have another person press and hold the ride control switch.

Terminal for wire 548B to ground 12 volts Check the circuit between the ride control solenoid and the ride control
switch (93) Frame 25. Also check the ride control switch (93) Frame 25.

NOTE: If the readings are ok, check with a screwdriver to see whether the solenoid magnetizes when energized. If not, replace the sole-
noid. If the solenoid magnetizes, the problem may be in the hydraulic system.

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54. RIDE CONTROL SOLENOID

ELECTRICAL SCHEMATIC FRAME 12

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55 Rotating Beacon Switch
Check Points Reading Possible Cause of Bad Readings

NOTE: Turn the ignition switch to the RUN position.

Terminal for wire 540C to ground 12 volts Check the circuit between the rotating beacon switch and the 10
ampere fuse in the options fuse block (12) Frame 2. Also check the
10 ampere fuse and options fuse block (12) Frame 2.

Place the rotating beacon switch in the 12 volts Bad rotating beacon switch.
ON position. If the readings are correct and the indicator lamp on the rotating bea-
Terminal for wire 766A to ground con switch does not illuminate, proceed to the next test

Terminal for wire 178AJ to ground Continuity Bad ground circuit for rotating beacon switch indicator lamp. Bad rotating
beacon switch.
If the readings are correct and the indicator lamp on the rotating bea-
con switch does not illuminate, replace the rotating beacon switch.

NOTE: If the readings were correct and the indicator lamp on the rotating beacon switch does not illuminate, replace the rotating bea-
con switch.

56 Rotating Beacon
Check Points Reading Possible Cause of Bad Readings

Between the terminals of the lamp Good Bad bulb.

Terminal for wire 178Y to ground Continuity Bad ground circuit.

NOTE: Turn the ignition switch to the RUN position. Place the rotating beacon switch in the ON position.

Terminal for wire 766A to ground 12 volts Check the circuit between the rotating beacon and the rotating beacon
switch (55). Also check the rotating beacon switch (55).

NOTE: If the readings are good, replace the rotating beacon.

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55. ROTATING BEACON SWITCH 56. ROTATING BEACON

ELECTRICAL SCHEMATIC FRAME 13

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Electrical Accessory Outlet (Optional)
Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178AD to ground Continuity Bad ground circuit.

NOTE: Turn the ignition switch to the ACC position.

Terminal for wire 817B to ground 12 volts Check the circuit between the accessory outlet and the 10 ampere fuse in
the options fuse block (12) Frame 2. Also check the 10 ampere fuse and
the options fuse block (12) Frame 2.

NOTE: If the readings are good, replace the electric accessory socket.

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ELECTRICAL SCHEMATIC FRAME 14

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57 Hydraulic Coupler Switch
Check Points Reading Possible Cause of Bad Readings

NOTE: Turn the ignition switch to the ON position.

Terminal for wire 178BF to ground Continuity Bad ground circuit.

Terminal for wire 540A to ground 12 volts Check the circuit between the hydraulic coupler switch and the 10
ampere fuse in the options fuse block (12) Frame 2. Also check the 10
ampere fuse and the options fuse block (12) Frame 2.

NOTE: Have another person hold the hydraulic coupler switch in the UNLATCH position.

Terminal for wire 547A to ground 12 volts Bad hydraulic coupler switch.

NOTE: Have another person hold the hydraulic coupler switch in the LATCH position.

Terminal for wire 547A to ground 0 volts Bad hydraulic coupler switch.

59 Hydraulic Coupler Release Solenoid

Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178BB to ground Continuity Bad ground circuit.

NOTE: Turn the ignition switch to the ON position. Have another person hold the hydraulic coupler switch in the UNLATCH position.

Terminal for wire 547 to ground 12 volts Check the circuit between the hydraulic coupler release solenoid (59)
and the hydraulic coupler switch (57). Also check the hydraulic coupler
switch (57).
If the readings are good, replace the hydraulic coupler release solenoid
(59).

NOTE: If the readings are ok, check with a screwdriver to see whether the solenoid magnetizes when energized. If not, replace the
solenoid. If the solenoid magnetizes, the problem may be in the hydraulic system.

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57. HYDRAULIC COUPLER SWITCH 59. HYDRAULIC COUPLER RELEASE SOLENOID

58. DIODE
ELECTRICAL SCHEMATIC FRAME 15

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Dome Lamp with Switch
Check Points Reading Possible Cause of Bad Readings

Bulb Continuity Bad bulb.

Terminal for wire 178Z to ground Continuity Bad ground circuit.

NOTE: Turn the ignition switch to the ON position.

Terminal for wire 540G to ground Approxi- Check the circuit between the dome lamp and the ignition switch (7)
mately 12 Frame 1. Also check the ignition switch (7) Frame 1.
volts

NOTE: If the readings are good, replace the dome lamp.

62 Fan Speed Switch

Check Points Reading Possible Cause of Bad Readings

NOTE: Turn the ignition switch to the ON position.

Terminal for wire ET000H to ground 12 volts Check the circuit between the heater blower switch and the 20 ampere
fuse in the primary fuse block (11) Frame 2. Also check the 20 ampere
fuse and the primary fuse block (11) Frame 2.

NOTE: Place the fan speed switch in the LOW position.

Terminal for wire ET003C to ground 12 volts Bad fan speed switch.

NOTE: Place the fan speed switch in the MEDIUM position.

Terminal for wire ET004C to ground 12 volts Bad fan speed switch.

NOTE: Place the fan speed switch in the HIGH position.

Terminal for wire ET005C to ground 12 volts Bad fan speed switch.

NOTE: If the readings are bad, replace the fan speed switch.

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61. HEAT CONTROL SWITCH 65. OPTION NOT AVAILABLE 410 AND 420
62. FAN SPEED SWITCH 66. OPTION NOT AVAILABLE 410 AND 420
63. BLOWER MOTOR 67. OPTION NOT AVAILABLE 410 AND 420
64. OPTION NOT AVAILABLE 410 AND 420
ELECTRICAL SCHEMATIC FRAME 16

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ELECTRICAL SCHEMATIC FRAME 17

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ELECTRICAL SCHEMATIC FRAME 18

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70 Starting Interlock Relay
Check Points Reading Possible Cause of Bad Readings

Terminal for wire 178DF to ground Continuity Bad ground circuit.

NOTE: Turn the ignition switch to the ON position. Have someone sit in the operators seat with the seat bar in the down position.

Terminal for wire 622D to ground Approxi- Check the circuit between the starting interlock relay and the ignition
mately 12 switch (7) Frame 1. Also check the ignition switch (7) Frame 1.
volts

Terminal for wire 624A to ground Approxi- Check the circuit between the starting interlock relay and the instrument
mately 12 cluster pin 26. Also check the instrument cluster pin 26.
volts

Terminal for wires 320A and 320B to Approxi- Bad starting interlock relay.
ground mately 12
volts

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69. AUXILIARY HYDRAULIC NEUTRAL SWITCH 71. FUEL SOLENOID RELAY

70. STARTING INTERLOCK RELAY 72. DIODE
ELECTRICAL SCHEMATIC FRAME 19

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73. HAZARD SWITCH 75. DIODE PACK

74. FLASHER MODULE
ELECTRICAL SCHEMATIC FRAME 20

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60. LEFT FRONT HEADLAMP 78. RIGHT FRONT TURNLIGHT

68. RIGHT FRONT HEADLIGHT 80. LEFT FRONT POSITION LIGHT
76. LEFT REAR TURNLIGHT 81. RIGHT FRONT POSITION LIGHT
77. RIGHT REAR TURNLIGHT 82. LICENSE PLATE LIGHT
78. LEFT FRONT TURNLIGHT 83. RESISTOR
ELECTRICAL SCHEMATIC FRAME 21

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BC04M092-22
84. LOADER LOCKOUT SWITCH (OPTIONAL)
ELECTRICAL SCHEMATIC FRAME 22

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BC04M092-23
85. NOT USED 87. RIGHT BRAKE LIGHT SWITCH (EURO)
86. LEFT BRAKE LIGHT SWITCH (EURO) 88. BRAKE LIGHT SWITCH TIMER RELAY (EURO)
ELECTRICAL SCHEMATIC FRAME 23

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90 Turn Signal Switch
Check Points Reading Possible Cause of Bad Readings

NOTE: Turn the ignition switch to the ON position.

Terminal for wire 540AA to ground Approximately Check the circuit between the turn signal switch and the 10 amp fuse in the
12 volts options fuse block (12) Frame 2. Also check the 10 amp fuse in the options
fuse block (12) Frame 2.

Place the turn signal switch in the LEFT Approximately Bad turn signal switch.
turn position. 12 volts Replace turn signal switch.
Terminal for wire 757AA to ground.

Place the turn signal switch in the RIGHT Approximately Bad turn signal switch.
turn position. 12 volts Replace turn signal switch.
Terminal for wire 756AA to ground.

91 Attachment Hydraulic Switch

Check Points Reading Possible Cause of Bad Readings

NOTE: Have another person sit in the operators seat. Pull the seat bar down to the operating position. Turn the ignition switch to the ON
position.

Push and release the hydraulic attachment Approximately Check the circuit for wire 311AB or 311BC or 311BD to the instrument clus-
switch. 12 volts ter connector pin 26.
Terminal for wire 311AB or 311BC or Also check the instrument cluster.
311BD to ground

Disconnect connector 123B or 123C or Approximately Bad hydraulic attachment switch.

123D. 12 volts
Have another person hold the switch in the
FORWARD flow position.
Terminal for wire 545AB or 545AC or
545AD to ground.

Have another person hold the switch in the Approximately Bad hydraulic attachment switch.
REVERSE flow position. 12 volts
Terminal for wire 546AB or 546AC or
546AD to ground.

98 Attachment Hydraulic Forward Flow “ON” Switch

Check Points Reading Possible Cause of Bad Readings

NOTE: Have another person sit in the operators seat. Pull the seat bar down to the operating position. Turn the ignition switch to the ON
position.

Push and release the hydraulic attachment Approximately Check the circuit for wire 311CB or 311CC or 311CD to the instrument clus-
forward flow “ON” switch. 12 volts ter connector pin 26.
Terminal for wire 311CB or 311CC or Also check the instrument cluster.
311CD to ground

Place the hydraulic attachment forward flow Approximately Bad hydraulic attachment forward flow “ON” switch.
“ON” switch in the FORWARD position. 12 volts
Terminal for wire 545BB or 545BC or
545BD to ground.

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89. TWO (2) SPEED SWITCH 91. ATTACHMENT HYDRAULIC SWITCH

90. TURN SIGNAL SWITCH 98. ATTACHMENT HYDRAULIC FORWARD FLOW “ON”
SWITCH
ELECTRICAL SCHEMATIC FRAME 24

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92 Horn Switch
Check Points Reading Possible Cause of Bad Readings

NOTE: Disconnect the horn switch connector.

Measure the resistance across the termi- Open Bad horn switch.
nals of the switch.

Have another person push and hold the Continuity Bad horn switch.
horn button down.
Measure the resistance across the termi-
nals of the switch.

NOTE: Reconnect the horn switch connector. Turn the ignition switch to the ON position.

Have another person push and hold the Approximately Check the circuit between the terminal for wire 892A and the horn button.
horn button down. 12 volts Check the circuit between the horn button and the 10 amp fuse in the pri-
Terminal for wire 892A at the horn. mary fuse block (11) Frame 2.
Also check the horn button.
Also check the 10 amp fuse in the primary fuse block (11) Frame 2.

94 Front Electric Control Switch No. 1

Check Points Reading Possible Cause of Bad Readings

NOTE: Turn the ignition switch to the ON position.

Terminal for wire 178BJ to ground Continuity Bad ground circuit.

NOTE: Turn the ignition switch to the ON position.

Terminal for wire 003O to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and
the front electric control switch No. 1.
Also check the front electric control switch No. 1.

NOTE: Turn the ignition switch to the ON position. Place the front electric control switch No. 1 in the UP position.

Terminal for wire 001B to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and
the front electric control switch No. 1.
Also check the front electric control switch No. 1.

NOTE: Turn the ignition switch to the ON position. Place the front electric control switch No. 1 in the DOWN position.

Terminal for wire 002D to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and
the front electric control switch No. 1.
Also check the front electric control switch No. 1.

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 4001-57
95 Front Electric Control Switch No. 2
Check Points Reading Possible Cause of Bad Readings

NOTE: Turn the ignition switch to the ON position. Place the front electric control switch No. 2 in the UP position.

Terminal for wire 004R to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and
the front electric control switch No. 2.
Also check the front electric control switch No. 2.

NOTE: Turn the ignition switch to the ON position. Place the front electric control switch No. 2 in the DOWN position.

Terminal for wire 005Y to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and
the front electric control switch No. 2.
Also check the front electric control switch No. 2.

96 Front Electric Control Switch No. 3

Check Points Reading Possible Cause of Bad Readings

NOTE: Turn the ignition switch to the ON position. Place the front electric control switch No. 3 in the UP position.

Terminal for wire 006P to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and
the front electric control switch No. 3.
Also check the front electric control switch No. 3.

NOTE: Turn the ignition switch to the ON position. Place the front electric control switch No. 3 in the DOWN position.

Terminal for wire 007T to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and
the front electric control switch No. 3.
Also check the front electric control switch No. 3.

97 Front Electric Control Switch No. 4

Check Points Reading Possible Cause of Bad Readings

NOTE: Turn the ignition switch to the ON position. Place the front electric control switch No. 4 in the ON position.

Terminal for wire 008W to ground 12 volts Check the circuit between the loader lift arm auxiliary electric connector and
the front electric control switch No. 4.
Also check the front electric control switch No. 4.

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4001-58

92. HORN SWITCH 95. FRONT ELECTRIC CONTROL SWITCH NO. 2

93. RIDE CONTROL SWITCH 96. FRONT ELECTRIC CONTROL SWITCH NO. 3
94. FRONT ELECTRIC CONTROL SWITCH NO. 1 97. FRONT ELECTRIC CONTROL SWITCH NO. 4
ELECTRICAL SCHEMATIC FRAME 25

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 4001-59

ELECTRICAL SCHEMATIC FRAME 26

Bur 6-79540 Issued 2-05 Printed in U.S.A.

4001-60

CONNECTORS Connector 7 Starter Relay

SCHEMATIC FRAME 1

Connector 4 Alternator

245731C1

Cavity Circuit ID Description

PAC_12186568 30 170A (R) 5.0 From 40 amp circuit

breaker to connector 7
Cavity Circuit ID Description pin 30

A 124A (R) 1.0 To connector 8A pin B4 85 178A (B) 2.0 From start relay to
ground
B 121B From Alternator to 50
ohm resistor 85 178B (B) 1.0 From start relay to main
power relay

86 622D (W) 1.0 To connector 127A pin B

87 625A (W) 3.0 From start relay to

starter solenoid

Connector 8
Cavity Circuit ID Description

A1 130B (R) 2.0 From connector 9 pin C

B2 131B (R) 1.0 From connector 9 pin B

A3 137A (R) 3.0 From connector 9 pin D

B3 622B (W) 1.0 From connector 9 pin A

256357A1

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 4001-61

Connector 8A Connector 9 Ignition Switch

256356A1 PAC_12052856

Cavity Circuit ID Description Cavity Circuit ID Description

A1 130A (R) 2.0 From 15 amp circuit A 622B (W) 1.0 To connector 8 pin B3
breaker
B 131B (R) 1.0 To connector 8 pin B2
B2 131A (R) 1.0 To connector 25pin A
C 130D (R) 2.0 To connector 8 pin A1
A3 137C (R) 3.0 To primary fuse block
D 137B (R) 0.8 to instrument cluster pin
terminal 2
10 “ACC”
B3 622A (W) 1.0 From connector 127pin
D 137A (R) 3.0 To connector 8 pin A3
B

Connector 52

FRA54201016

Cavity Circuit ID Description

8 137K (R) 1.0 To connector 21

9 121A (Y) 1.0 To connector 20

10 625A (W) 3.0 To connector 7 pin 85

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4001-62

Connector 52A Connector 25

FRA54201009 CNH_STYLE_24

Cavity Circuit ID Description Cavity Circuit ID Description

9 121B (Y) 1.0 From connector 4 pin B A 131A (R) 1.0 From connector 8A pin
B2
10 625D (W) 5.0 From connector 106
B 131C (R) 1.0 To connector 14 pin 86

CONNECTORS
SCHEMATIC FRAME 2 Connector 64 Options Power Relay

Connector 14 Main Power Relay

245731C1

Cavity Circuit ID Description

245731C1

30 180A (R) 5.0 From 40 amp circuit

Cavity Circuit ID Description breaker

30 180A (R) 5.0 From 40 amp circuit 85 178H (B) 1.0 To ground
breaker
86 137D (R) 1.0 From connector 17A
85 178B (B) 1.0 To ground pin A

85 178E (B) 1.0 To ground 87 138A (R) 5.0 To options fuse block T3

86 131C (R) 1.0 To reverse polarity diode

connector 25 pin B

87 136A (R) 5.0 To primary fuse block T4

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 4001-63

CONNECTORS Connector 8
SCHEMATIC FRAME 3

Connector 60

Cavity Circuit ID Description

1 IVC2 (B) 0.8 From splice

2 IVC4 (B) 0.8 To cold start advance

solenoid

256357A1

Cavity Circuit ID Description

CONNECTORS
C1 311D (T) 1.0 To connector 50 pin B
SCHEMATIC FRAME 5
D2 300E (R) 1.0 To connector 23 pin 24
Connector 8A “IGN ON”

C2 303C (T) 0.5 To connector 59 pin A

D4 258C (T) 0.5 To connector 23 pin 8

J2 602B (W) 0.5 To connector 23 pin 5

D1 319A (T) 0.5 To connector 23 pin 26

H2 311C (T) 1.0 To connector 50 pin A

256356A1

Cavity Circuit ID Description

C1 311F (T) 1.0 From splice 14

D2 300D (R) 1.0 From splice

C2 303D (T) 1.0 From connector 18 pin

86

D4 258B (T) 1.0 From connector 80 pin 1

J2 602A (W) 1.0 From connector 127 pin

A

D1 319B (T) 1.0 From connector 79 pin A

H2 311B (P) 1.0 From connector 18 pin

87

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4001-64

Connector 18 Interlock Relay Connector 50

245731C1 CNH_STYLE_24

Cavity Circuit ID Description Cavity Circuit ID Description

30 300B (R) 2.0 From splice A 311C (T) 1.0 From connector 8 pin H2

85 178E (B) 1.0 To ground B 311D (T) 1.0 From connector 8 pin J2

86 303D (T) 1.0 To connector 8A pin C2

87 311B (P) 1.0 To connector 8A pin H2

Connector 23 Instrument Cluster

AMP_3_1437290_8

Cavity Circuit ID Description

12 323A (T) 0.5 From connector 58 pin B

14 313D (T) 0.8 To connector 59 pin A

8 258C (T) 0.5 To connector 8 pin D4

5 602B (W) 0.5 To connector 8 pin J2

26 319A (T) 0.5 To connector 8 pin D1

4 754A (P) 0.5 To connector 97A pin B

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 4001-65

Connector 57 Connector 59

256340A1 253294A1

Cavity Circuit ID Description Cavity Circuit ID Description

A 178K (B) 1.0 To ground A 313D (T) 0.8 To connector 23 pin 14

seat bar switch
B 311G (T) 1.0 From splice 14
B 303C (T) 0.8 From connector 8 pin C2

Connector 58
Connector 79

253294A1‘

256340A1
Cavity Circuit ID Description
Cavity Circuit ID Description
A 130E (R) 0.8 From splice
A 319C (T) 1.0 From connector 8 pin D1
B 323A (T) 0.8 To connector 23 pin 12
B 565A (T) 1.0 From connector 48 pin B

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4001-66

Connector 80 Connector 127

225316C1 256346A1

Cavity Circuit ID Description Cavity Circuit ID Description

1 258B (T) 1.0 From connector 8A pin A 602A (W) 1.0 From connector 8A pin
D4 J2

2 178CJ (B) 1.0 To ground B 622A (W) 1.0 From connector 8A pin
B3

C 319D (T) 1.0 From splice

D 178CJ (B) 1.0 To ground

Connector 103
Connector 127A

256340A1

256346A1
Cavity Circuit ID Description
Cavity Circuit ID Description
A 178D (B) 1.0 To ground
A 602G (W) 1.0 To fuel hold-in solenoid
B 311H (T) 1.0 From splice 14
B 622D (W) 1.0 From start relay
connector 7 pin 86

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 4001-67

CONNECTORS Connector 8A
SCHEMATIC FRAME 6

Connector 8

256356A1

Cavity Circuit ID Description

256357A1 D3 641A (W) 1.0 To grid heater relay

Cavity Circuit ID Description G2 261A (Y) 1.0 From hydraulic filter

pressure switch
D3 641B (W) 0.5 To connector 23 pin 7
G4 264A (Y) 1.0 From hydraulic oil
G2 261B (Y) 0.5 To connector 23 pin 15 temperature sender

G4 264B (Y) 0.5 To connector 23 pin 2 G1 257A (Y) 1.0 From engine coolant
temperature sender
G1 257B (Y) 0.5 To connector 23 pin 25
J1 266A (Y) 1.0 From air filter restriction
J1 266B (Y) 0.5 To connector 23 pin 16 switch
F1 234B (Y) 0.5 To connector 23 pin 1 F1 234A (Y) 1.0 From fuel sender
E4 255B (Y) 0.5 To connector 23 pin 18 E4 255A (Y) 1.0 From engine oil pressure
switch
G3 262A (Y) 0.5 To connector 23 pin 17
G3 262B (Y) 1.0 From charge pressure
B4 124B (R) 0.5 To connector 23 pin 19
switch
K1 200C (B/W) 0.5 To connector 23 pin 20
B4 124C (R) 1.0 From connector 52 pin 4

K1 200D (B/W) To ground

1.0

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4001-68

Connector 23 Instrument Cluster Connector 29

AMP_3-1437290-8 291718A1

Cavity Circuit ID Description Cavity Circuit ID Description

3 130C (R) 0.5 From splice 1 266C (Y) 1.0 To connector 52A pin 1

24 300H (R) 0.5 From splice (Key “ON”) 2 178G (B) 1.0 to ground

23 300G (R) 0.5 From splice (Key “ON”)

10 137B (R) 0.8 Form connector 9 pin D

(Key “ACC”)
Connector 30
21 781A (P) 0.5 To connector 8 pin H1

22 782A (P) 0.5 To connector 8 pin E1

7 641B (W) 0.5 To connector 8 pin D3

15 261B (Y) 0.5 To connector 8 pin G2

2 264B (Y) 0.5 To connector 8 pin G4

25 257B (Y) 0.5 To connector 8 pin G1

16 266B (Y) 0.5 To connector 8 pin J1

1 234B (Y) 0.5 To connector 8 pin F1 245482C1

18 255B (Y) 0.5 To connector 8 pin E4 Cavity Circuit ID Description

17 262A (Y) 0.5 To connector 8 pin G3 A 178CK (B) To ground

1.0
19 124B (R) 0.5 To connector 8 pin B4
B 262B (Y) 1.0 From connector 8A pin
20 200C (B/W) Clean ground G3
0.5

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 4001-69

Connector 52 Connector 52A

FRA_54201009 FRA_54201016

Cavity Circuit ID Description Cavity Circuit ID Description

1 266A (Y) 1.0 From connector 8A pin 1 266C (Y) 1.0 From connector 29 pin 1
J1
2 255C (Y) 1.0 From connector 27 pin
2 255A (Y) 1.0 From connector 8A pin
E4 3 257C (Y) 1.0 From connector 26

3 257A (Y) 1.0 From connector 8A pin 4 124A (R) 1.0 From connector 4 pin A
G1 Alternator

4 124C (R) 1.0 From connector 8A pin

B4

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4001-70

CONNECTORS Connector 32
SCHEMATIC FRAME 7

Connector 8

256340A1

Cavity Circuit ID Description

256357A1 A 178X (B) 1.0 To ground

Cavity Circuit ID Description B 783F (P) 1.0 From connector 8 pin A2

E1 782A (P) 0.5 From connector 23 pin

22

H1 781A (P) 0.5 From connector 23 pin

21 Connector 33
A2 783E (P) 2.0 To connector 32 pin A

Connector 8A

256340A1

Cavity Circuit ID Description

A 784A (P) 1.0 From connector 93 pin

87A

B 178F To connector 38
256356A1

Cavity Circuit ID Description

E1 782B (P) 0.8 To connector 96 pin 86

H1 781B (P) 0.8 From connector 99 pin A

A2 783D (P) 2.0 To connector 96 pin 87

Bur 6-79540 Issued 2-05 Printed in U.S.A.

 4001-71

Connector 34 Connector 96

256340A1 245731C1

Cavity Circuit ID Description Cavity Circuit ID Description

A 783G (P) 1.0 From splice 30 780A (R) 3.0 From primary fuse block
T1
B 178R (B) 1.0 To ground
85 178AU (B) To connector 93 pin 85
0.8

87 783A (P) 3.0 From connector 8A pin

A2
Connector 93
86 782B (P) 0.8 From connector 8A pin
E1

86 782C (P) 0.8 To connector 99 pin B

245731C1

Cavity Circuit ID Description

85 178U (B) 0.8 To ground

87 706A (P) 3.0 To connector 102 pin 1

87A 784A (P) 2.0 To connector 101B

30 783B (P) 2.0 From splice

85 178U (B) 1.0 To ground

86 781C (P) 0.8 To connector 99 pin A

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4001-72

Connector 99 CONNECTORS
SCHEMATIC FRAME 10

Connector 50A

CNH_STYLE_24

Cavity Circuit ID Description

A 781B (P) 0.8 From connector 8A pin CNH_STYLE_24

E1
Cavity Circuit ID Description
A 781C (P) 0.8 From connector 93 pin
86 A 313F (T) 1.0 From connector 140 pin
1
B 782C (P) 1.0 From connector 96 pin
86 B 313J (T) 1.0 From connector 140 pin
2

CONNECTORS
SCHEMATIC FRAME 8 Connector 51

Connector 39 (Grey)

225295C1

Cavity Circuit ID Description

256340A1
A 313H (T) 1.0 From connector 140A
Cavity Circuit ID Description pin 2

A 890A (R) 1.0 From primary fuse block B 313G (T) 1.0 From connector 140A
T7 pin 1

B 892C (O) 1.0 To horn

Bur 6-79540 Issued 2-05 Printed in U.S.A.

 4001-73

Connector 51A Connector 65A

225295C1 182069A1

Cavity Circuit ID Description Cavity Circuit ID Description

A COM (B) 1.0 To door switch COM A 830C (R) 2.0 To connector 140 pin 5
Terminal
B 178WH (B) From connector 113 pin
B NO (W) 1.0 To door switch NO 1.0 1
Terminal

C NC (R) 1.0 To door switch NC

Terminal

Connector 112

Connector 65

239451A1

Cavity Circuit ID Description

182069A1 2 837a (w) 1.0 To connector 141 pin B

Cavity Circuit ID Description 3 830F (R) 2.0 From connector 141 pin
8
A 830B (R) 3.0 From primary fuse block
T3 4 178WP (B) From connector 140A
1.0 pin 6
B 178T (B) 3.0 To ground

Bur 6-79540 Issued 2-05 Printed in U.S.A.

4001-74

Connector 113 Connector 140A

1 2

AMP_480115_1 225350C1

Cavity Circuit ID Description Cavity Circuit ID Description

1 178WH (B) From connector 65A pin 1 313G (T) 1.0 To connector 51 pin B
1.0 B
2 313H (T) 1.0 To connector 51 pin A
1 178G (B) 1.0 From connector 140 pin
6 3 835A (O) 1.0 From connector 141 pin
7
2 835B (O) 1.0 To connector 140 pin 3
5 830D (R) 2.0 From connector 141 pin
3

6 178WP (B) To connector 112 pin 4

1.0
Connector 140

Connector 141 Wiper/Washer

Switch

Cavity Circuit ID Description

3 830E (R) 1.0 To connector 141 pin 8

3 830D (R) 2.0 To connector 140A pin 5

225351C1
4 837A (W) 1.0 To connector 112 pin 2
Cavity Circuit ID Description 7 835A (O) 1.0 To connector 140A pin 3
1 313F (T) 1.0 To connector 50A pin A 8 830F (R) 2.0 To connector 112 pin 3
2 331J (T) 1.0 To connector 50A pin B 8 830E (R) 1.0 To connector 141 pin 3
3 835B (O) 1.0 To connector 113 pin 2

5 830C (R) 2.0 To connector 65A pin A

6 178WG (B) To connector 113 pin 1

1.0

Bur 6-79540 Issued 2-05 Printed in U.S.A.

 4001-75

CONNECTORS Connector 72
SCHEMATIC FRAME 11

Connector 70

245432C1

Cavity Circuit ID Description

DE_HDP26-24-21S A 535A (T) 1.0 To connector 70 pin V

Cavity Circuit ID Description B 751E (R) 1.0 From options fuse block
T6
V 535A (T) 1.0 From connector 72 pin A
C 178CG (B) To ground
U 751E (R) 1.0 From connector 72 pin B 0.8

Connector 70A Connector 81

DE_HDP24-24-21P 225316A1

Cavity Circuit ID Description Cavity Circuit ID Description

V 535B (T) 1.0 To connector 81 pin 2 1 178CF (B) To ground

1.0
U 751E (R) 1.0 From options fuse block
T6 2 535B (T) 1.0 To connector 70A pin V

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4001-76

Connector 81B Connector 121

225315C1 291718A1

Cavity Circuit ID Description Cavity Circuit ID Description

1 178DA (B) From splice 1 178DC (B) From splice

1.0 1.0

2 535D (T) 1.0 To connector 124 pin B 2 545B (T) 1.0 To connector 123 pin A

Connector 120 Connector 122

245482C1 291718A1

Cavity Circuit ID Description Cavity Circuit ID Description

A 535C (T) 1.0 From connector 124 pin 1 178DD (B) To connector 124 pin A
B 1.0

B 178D (B) 1.0 From splice 2 546B (T) 1.0 From connector 123 pin
B

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 4001-77

Connector 123 CONNECTORS

SCHEMATIC FRAME 12

Connector 77

253294A1

Cavity Circuit ID Description

A 545B (T) 1.0 To connector 121 pin 2 256340A1

B 546B (T) 1.0 To connector 122 pin 2 Cavity Circuit ID Description

B 548B (T) 1.0 To ride control solenoid

Connector 124
CONNECTORS
SCHEMATIC FRAME 13

Connector 67

CNH_STYLE-24

Cavity Circuit ID Description

A 178DE (B) From connector 12 pin 1

1.0
245781C1

B 535D (T) 1.0 From connector 81B pin

2 Cavity Circuit ID Description

B 535C (T) 1.0 From connector 120 pin A 178AJ (B) To ground
A 0.8

E 540F (R) 1.0 To connector 70 pin A

E 540G (R) 1.0 From options fuse block

T8

D 766A (P) 1.0 To connector 68 pin B

Bur 6-79540 Issued 2-05 Printed in U.S.A.

4001-78

Connector 68 Connector 71A (Euro)

CNH_STYLE-24 877290R1

Cavity Circuit ID Description Cavity Circuit ID Description

A 178AF (B) To ground B 817D (R) 1.0 From options fuse block
1.0 T2

A 178BZ (B) To connector 69 pin A A 178BZ (B) To ground

1.0 1.0

B 766A (P) 1.0 From connector 67 pin D

(rotating beacon switch)

CONNECTORS
SCHEMATIC FRAME 15
CONNECTORS
SCHEMATIC FRAME 14 Connector 70

Connector 71

DE_HDP26-24-21S

Cavity Circuit ID Description

877291R1
S 540A (R) 1.0 From connector 75 pin A
Cavity Circuit ID Description
C 547A (T) 1.0 From connector 75 pin B
B 817B (R) 1.0 From options fuse block
T2

A 178AD (B) To ground

1.0

Bur 6-79540 Issued 2-05 Printed in U.S.A.

 4001-79

Connector 70A Connector 75

DE_HDP24-24-21P 245432C1

Cavity Circuit ID Description Cavity Circuit ID Description

S 540B (R) 1.0 From options fuse block D 178BF (B) To ground
T8 0.8

C 547B (T) 1.0 From connector 115 pin A 547A (T) 1.0 To connector 70 pin C
A
B 540A (R) 1.0 To connector 70 pin S

Connector 73
Connector 76

CNH_STYLE-24
225316C1

Cavity Circuit ID Description

Cavity Circuit ID Description
A 178BB (B) From connector 76 pin 2
0.8 1 547E (B) 0.8 From connector 73 pin B

B 547E (B) 0.8 From connector 76 pin 1 2 178BB (B) To connector 73 pin A
0.8
A 178BA (B) From connector 115A
1.0 pin B

B 547D (T) 0.8 To connector 115A pin A

Bur 6-79540 Issued 2-05 Printed in U.S.A.

4001-80

Connector 115 CONNECTORS

SCHEMATIC FRAME 16

Connector 69

256340A1

Cavity Circuit ID Description

A 547B (T) 1.0 From connector 70A pin CNH_STYLE-24

C
Cavity Circuit ID Description
B 178AF (B) To ground
1.0 A 178BZ (B) To connector 68 pin A
1.0

B 540G (R) 1.0 From connector 67 pin E

Connector 115A

Connector 117

256341A1

Cavity Circuit ID Description

877291R1

A 547D (T) 1.0 From connector 73 pin B

Cavity Circuit ID Description
B 178BA (B) To connector 73 pin A
1.0 A 178CE (B) To ground
2.0

B 540G (R) 1.0 From connector 67 pin E

Bur 6-79540 Issued 2-05 Printed in U.S.A.

 4001-81

Connector 117A Connector 171

Cavity Circuit ID Description Cavity Circuit ID Description

A ET000B (R) To connector 176 pin A B ET001C (R) From connector 170 pin
0.8 0.8 3

A ET000A (B) To connector 174 pin D B ET001A (R) From connector 117A
2.0 2.0 pin B

B ET001A (R) To connector 171 pin B C ET007A (R) To connector 172 pin A
2.0 1.0

B ET001B (R) To connector 176 pin C L ET003A (P) To connector 174 pin E
0.8 2.0

M ET004A (Y) To connector 174 pin B

2.0

H ET005A (O) To connector 174 pin C

Connector 170 2.0

Cavity Circuit ID Description

1 ET000E (B) From connector 172 pin

0.8 B

2 ET006A (Y) To connector 176 pin B

0.8

3 ET001C (R) To connector 171 pin B

0.8

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4001-82

Connector 174 Connector 176

Cavity Circuit ID Description Cavity Circuit ID Description

E ET003A (P) From connector 171 pin A ET000B (R) To connector 117A pin A
2.0 L 0.8

B ET004A (Y) From connector 171 pin B ET006A (Y) From connector 170 pin
2.0 M 0.8 2

C ET005A (O) From connector 171 pin C ET001B (R) From connector 117A
2.0 H 0.8 pin B

D ET000C (B) From connector 17A pin

1.0 A

A ET008A (LB) From connector 172 pin

1.0 B CONNECTORS
F ET009A (LB) From air conditioner
SCHEMATIC FRAME 17
1.0 pressure switch
Connector 66

Connector 175

Cavity Circuit ID Description

E ET003C (P) To connector 179 blower

2.0 motor

B ET004C (Y) To connector 178 blower

2.0 motor
256351A1

C ET005C (O) To connector 177 blower

2.0 motor Cavity Circuit ID Description

D ET000H (B) From connector 180 A 757B (P) 1.0 To connector 85 pin A
2.0 blower motor
B 751G (R) 1.0 To connector 85 pin B
A ET008C (LB) To connector 181
C 756B (P) 1.0 To connector 85 pin C
1.0 thermostat

F ET009C (LB) From connector 182

1.0 thermostat

Bur 6-79540 Issued 2-05 Printed in U.S.A.

 4001-83

Connector 66A Connector 85

256350A1 256345A1

Cavity Circuit ID Description Cavity Circuit ID Description

A 757A (P) 1.0 To connector 86 pin A A 757B (P) 1.0 To connector 85A pin A
option A or connector
B 751F (R) 1.0 From options fuse block 85D pin A option D
T6
B 751G (R) 1.0 To connector 85A pin B
C 756A (P) 1.0 To connector 86 pin C option A or connector
85D pin B option D
D 759A (P) 1.0 From connector 70A pin
L C 756B (P) 1.0 To connector 85A pin C
option A or connector
E 758B (P) 1.0 To connector 70A pin K 85D pin C option D
F 754C (P) 1.0 To connector 70A pin N

H 178AN (B) To ground

1.0
Connector 86

256345A1

Cavity Circuit ID Description

A 757A (P) 1.0 To connector 86B pin A

B 178AG (B) To ground

1.0

C 756A (P) 1.0 To connector 86B pin C

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CONNECTORS Connector 107

SCHEMATIC FRAME 18

Connector 49

225233C1

Cavity Circuit ID Description

225320C1 E 001B (B) 1.0 From connector 138 pin

1
Cavity Circuit ID Description
F 002B (DB From connector 138 pin
1 001A (B) 1.0 To connector 138A pin 1 1.0 2

2 002A (DB) To connector 138A pin 2 K 817J (O) 2.0 From connector 138 pin
1.0 3

3 003D (O) 1.0 To connector 138A pin 3 G 004B (R) 1.0 From connector 138 pin
4
4 004A (R) 1.0 To connector 138A pin 4
H 005B (Y) 1.0 From connector 138 pin
5 005A (Y) 1.0 To connector 138A pin 5 5
6 006A (P) 1.0 To connector 138A pin 6 C 006B (P) 1.0 From connector 138 pin
6
7 007A (T) 1.0 To connector 138A pin 7
D 007B (T) 1.0 From connector 138 pin
8 008A (W) 1.0 To connector 138A pin 8
7

J 008B (W) 1.0 From connector 138 pin

8

B 178JH (B) From connector 138 pin

2.0 9

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 4001-85

Connector 138 Connector 138A

225389C1 225388C1

Cavity Circuit ID Description Cavity Circuit ID Description

1 001B (B) 1.0 To connector 107 pin E 1 001A (B) 1.0 From connector 49 pin 1

2 002B (DB To connector 107 pin F 2 002A (DB From connector 49 pin 2
1.0 1.0

3 817J (O) 2.0 To connector 107 pin K 3 817H (O) 2.0 From connector 49 pin 3

4 004B (R) 1.0 To connector 107 pin G 4 004A (R) 1.0 From connector 49 pin 4

5 005B (Y) 1.0 To connector 107 pin H 5 005A (Y) 1.0 From connector 49 pin 5

6 006B (P) 1.0 To connector 107 pin C 6 006A (P) 1.0 From connector 49 pin 6

7 007B (T) 1.0 To connector 107 pin D 7 007A (T) 1.0 From connector 49 pin 7

8 008B (W) 1.0 To connector 107 pin J 8 008A (W) 1.0 From connector 49 pin 8

9 178JH (B) To connector 107 pin B 9 178HJ (B) To ground

2.0 2.0

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Connector 150 CONNECTORS

SCHEMATIC FRAME 19

Connector 125

182069A1

Cavity Circuit ID Description

A 817F (R) 2.0 From options fuse block 245731C1

T2
Cavity Circuit ID Description
B 178BJ (B) To ground
2.0 85 178DF (B) From connector 127B
1.0 pin D

85 178DG (B) From connector 128 pin

1.0 85

Connector 150A 86 320B (LB) From connector 129 pin

1.0 A

30 622D (W) To connector 127B pin B

1.0

86 320A (LB) To connector 130 pin B

1.0

87 624A (DB) To connector 127B pin B

1.0

182069A1

Cavity Circuit ID Description

A 817G (O) From splice 15

B 178HJ (B) To connector 138A pin 9

2.0

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 4001-87

Connector 127B Connector 128

256347A1 245731C1

Cavity Circuit ID Description Cavity Circuit ID Description

A 602D (W) From connector 128 pin 85 178 DG (B) From connector 125 pin
1.0 30 1.0 85

B 622D (W) From connector 125 pin 86 319F (T) 1.0 From connector 129 pin
1.0 30 B

C 319E (T) 1.0 From connector 129 pin 30 602F (W) 1.0 From splice
B
87 604A (W) 1.0 To connector 127C pin A
D 178DF (B) From connector 125 pin
1.0 85

Connector 129
Connector 127C

CNH_STYLE_30

256346A1 Cavity Circuit ID Description

Cavity Circuit ID Description A 320B (LB) From connector 125 pin

1.0 86
A 604A (W) 1.0 From connector 128 pin
87 B 319E (T) 1.0 To connector 127B pin C

B 624A (DB) From connector 125 pin B 319F (T) 1.0 To connector 128 pin 86
1.0 87

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4001-88

Connector 130 Connector 66C

256341A1 256351A1

Cavity Circuit ID Description Cavity Circuit ID Description

B 320A (LB) To connector 125 pin 86 B 751FA (R) From connector 275 pin
1.0 1.0 86

A 602E (W) 1.0 From splice C 756FA (P) From connector 66B pin
1.0 C

E 758FA (P) From connector 276 pin

1.0 B

CONNECTORS H 178FA (B) From connector 275 pin

SCHEMATIC FRAME 20 1.0 85

A 757FA (P) From connector 66B pin

Connector 66B 1.0 A

D 759FB (P) From splice F1

1.0

F 754FA (P) To connector 276 pin E

1.0

256350A1

Cavity Circuit ID Description

A 757FB (P) From splice F3

1.0

B 759FA (P) From splice F1

1.0

C 756FB (P) From splice F2

1.0

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 4001-89

Connector 92 Connector 276

245781C1 245488C1

Cavity Circuit ID Description Cavity Circuit ID Description

A 178AL (B) To ground A 756FC (P) From splice F2

0.8 1.0

D 758A (P) 1.0 To connector 70 pin K C 757FC (P) From splice F3

1.0
E 759A (P) 1.0 To connector 70 pin L
E 754FA (P) To connector 66C pin F
1.0

B 758FA (P) To connector 66C pin E

1.0
Connector 275
D 756FD (P) From splice F2
1.0

F 757FD (P) From splice F3

1.0

245731C1

Cavity Circuit ID Description

85 178FA (B) To connector 66C pin H

1.0

86 751FA (R) To connector 66C pin B

1.0

87 759FC (P) To connector 66C pin D

1.0

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CONNECTORS Connector 226

SCHEMATIC FRAME 21

Connector 86B

225326C1

Cavity Circuit ID Description

256344A1 1 178TB (B) From splice T1

1.0
Cavity Circuit ID Description
2 706TB (P) From splice T3
C 757TC (P) To connector 227 pin 4 1.0
1.0
3 701TA (P) To connector 250A
B 178TE (B) To connector 227 pin 1 1.0
1.0
4 756TB (P) From splice T1
A 756TC (P) From splice T1 1.0
1.0

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 4001-91

Connector 227 Connector 228

225326C1 277905A1

Cavity Circuit ID Description Cavity Circuit ID Description

1 178TG (B) From splice T6 2 178TA (B) From splice T5

1.0 1.0

2 706TF (P) From splice T4 1 706TH (P) From splice T3

1.0 1.0

3 701TB (P) From connector 250A 3 756TA (P) From splice T1

1.0 1.0

4 757TB (P) From splice T2 4 706TA (P) To connector 228 pin 1

1.0 1.0

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4001-92

Connector 229 CONNECTORS

SCHEMATIC FRAME 22

Connector 50C

277905A1

Cavity Circuit ID Description

2 178TH (B) From splice T7 CNH_STYLE_24

1.0
Cavity Circuit ID Description
4 706TG (P) To connector 229 pin 1
1.0 A 12B (T) 1.0 To connector 229 pin E

3 757TA (P) From splice T2 B 13A (T) 1.0 To connector 50D pin B
1.0

1 706TJ (P) From splice T4

1.0

Connector 50D

Connector 230

CNH_STYLE_24

Cavity Circuit ID Description

245482C1
A 13B (T) 1.0 From connector 1189 pin
F
Cavity Circuit ID Description
B 13A (T) 1.0 To connector 50C pin B
A 706TC (P) From connector 102B
1.0

B 178TC (B) From splice T5

1.0

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 4001-93

Connector 119 Connector 71C

245781C1 877290R1

Cavity Circuit ID Description Cavity Circuit ID Description

E 12B (T) 1.0 To connector 50C pin A A 178EA (B) From connector 190 pin
1.0 85
F 13B (T) 1.0 To connector 50D pin A
A 178EB (B) From connector 71B pin
1.0 A

B 700A (P) 1.0 To right brake light

switch
CONNECTORS
SCHEMATIC FRAME 23 B 700B (P) 1.0 To connector 71B pin B

Connector 71B (Euro)

Connector 190 (Euro)

872291R1

Cavity Circuit ID Description

245731C1
A 178EB (B) From connector 71C pin
1.0 A Cavity Circuit ID Description

B 700B (P) 1.0 From connector 71C pin 86 702A (P) 1.0 To connector 250
B
87 701A (P) 1.0 To left brake light switch

85 178EA (B) To connector 71C pi n A

1.0

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4001-94

CONNECTORS Connector 79D

SCHEMATIC FRAME 24

Connector 79B

256341A1

Cavity Circuit ID Description

256341A1 B 565AD (T) To 2 speed switch

0.8 (option D)
Cavity Circuit ID Description
A 311AD (R) To attachment hydraulic
A 311AB (R) To attachment hydraulic 1.0 forward flow “ON” switch
1.0 forward flow “ON” switch (option D)
(option B)

Connector 85A
Connector 79C

256344A1
256341A1

Cavity Circuit ID Description

Cavity Circuit ID Description
C 756AA (LB) From turn signal switch
B 565AC (T) To 2 speed switch 0.8 (option A)
1.0 (option D)
B 540AA (O) To turn signal switch
A 311AC (R) To attachment hydraulic 0.8 (option A)
1.0 forward flow “ON” switch
(option D) A 757AA (Y) From turn signal switch
0.8 (option A)

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 4001-95

Connector 85D Connector 123C

256344A1 256294A1

Cavity Circuit ID Description Cavity Circuit ID Description

A 757AD (Y) From turn signal switch A 545AC(Y) From attachment

1.0 (option D) 1.0 hydraulic switch (option
C)
B 540AD (O) To turn signal switch
0.8 (option D) B 546AC (LB) From attachment
1.0 hydraulic switch (option
C 756AD (LB) From turn signal switch C)
0.8 (option D)

Connector 123D
Connector 123B

256294A1
256294A1

Cavity Circuit ID Description

Cavity Circuit ID Description
A 545AD(Y) From attachment
B 545AB (Y) From attachment 1.0 hydraulic switch (option
1.0 hydraulic switch (option D)
B)
B 546AD (LB) From attachment
A 546AB (LB) From attachment 1.0 hydraulic switch (option
1.0 hydraulic switch (option D)
B)

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4001-96

CONNECTORS Connector 39H

SCHEMATIC FRAME 25

Connector 39F

253294A1

Cavity Circuit ID Description

253294A1 A 890AH (R) From horn switch (option

1.0 H)
Cavity Circuit ID Description
B 892AH (V) From horn switch (option
A 890AF (R) From horn switch (option 1.0 H)
1.0 F)

B 892AF (V) From horn switch (option

1.0 F)

Connector 39G

253294A1

Cavity Circuit ID Description

A 890AG (R) From horn switch (option

1.0 G)

B 892AG (V) From horn switch (option

1.0 G)

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 4001-97

Connector 49H Connector 77H

DEU_DT06-8S 256341A1-

Cavity Circuit ID Description Cavity Circuit ID Description

1 001(B) 0.8 From front electric B 548AH (V) From ride control switch
control switch No. 1 1.0 (option H)
(option H)

2 002 (DB) 0.8 From front electric

control switch No. 1
(option H)

3 003 (0) 0.8 To front electric control

switch No. 1 (option H)

4 004 (R) 0.8 From front electric

control switch No. 2
(option H)

5 005 (Y) 0.8 From front electric

control switch No. 2
(option H)

6 006 (P) 0.8 From front electric

control switch No. 3
(option H)

7 007 (T) 0.8 From front electric

control switch No. 3
(option H)

8 008 (W) 0.8 From front electric

control switch No. 4
(option H)

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4001-98

ELECTRONIC INSTRUMENT CONSOLE (EIC)

BD05A089
1. KEY SWITCH 2. INSTRUMENT (EIC) PANEL

SWITCH PANEL

1
2 4
3 5
6
7
8

BD04N043
1. TEMPERATURE CONTROL
2. BLOWER FAN SWITCH
3. AIR CONDITIONING SWITCH (IF EQUIPPED)
4. BLANK FOR SWITCH
5. HYDRAULIC COUPLER SWITCH (IF EQUIPPED)
6. ROTATING BEACON SWITCH LOCATION (IF EQUIPPED)
7. HAZARD FLASHER SWITCH LOCATION (IF EQUIPPED)
8. HIGH/LOW HYDRAULIC CONTROL SWITCH (IF
EQUIPPED)

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 4001-99

ELECTRONIC INSTRUMENT PANEL (EIC)

1
2 14
11 15
12 10
13 3
4 5
8 6
7
9

BD05A089
1. SEAT BELT INDICATOR LAMP
2. ENGINE OIL PRESSURE INDICATOR LAMP AND ALARM
3. PARK BRAKE INDICATOR LAMP
4. FUEL GUAGE
5. HOURMETER
6. ROAD LAMP SWITCH
7. AUXILIARY HYDRAULIC INTERLOCK OVERRIDE SWITCH
8. WORK LAMP SWITCH
9. PARK BRAKE “ON/OFF” SWITCH
10. HYDRAULIC OIL FILTER WARNING LAMP
11. COOLANT TEMPERATURE WARNING LAMP AND ALARM
12. ENGINE AIR FILTER WARNING LAMP
13. ENGINE PREHEATER LAMP (IF EQUIPPED)
14. CHARGE PRESSURE WARNING LAMP
15. HYDRAULIC FLUID TEMPERATURE WARNING LAMP

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4001-100

ELECTRONIC INSTRUMENT CLUSTER (EIC) OPERATING INSTRUCTIONS

The EIC monitors and controls certain loader A. (6) Work lights (ON/OFF)
functions and engine parameters. When a monitored B. (8) Road lights (ON/OFF)
parameter limit is exceeded, the EIC issues audible
and visual warnings to the operator. C. (9) Parking brake (SET/RELEASE)
D. (7) Auxiliary hydraulic interlock override.
Monitored functions and parameters:
1. Operator (in/out seat) – lighted indicator Push Button Functional Description:
2. Operator seat restraint bar (up/down), – lighted Work lights and road lights – toggles the state of
indicator (same as lighted indicator in (1). the lights indicated by an associated LED. Only
3. Engine oil pressure (high/low) – lighted indicator. works when the ignition key is ON.
4. Hydraulic charge pressure (high/low) – lighted Parking brake – for machines with hydraulically
indicator. actuated brake, this button toggles the state of the
5. Hydraulic oil temperature (high/low) – lighted parking brake. A back lighted symbol displays the
indicator. state of the brake. At power up, loader motion,
hydraulic flow to attachments and movement of the
6. Engine coolant temperature (high/low) – lighted
boom and bucket are inhibited until this button is
indicator.
pushed. At power up only, a flashing LED near this
7. Hydraulic oil filter condition (free/restricted) – push button prompts the operator to release the
lighted indicator. brake to begin operation. This function only works
8. Engine air filter condition (free/restricted) – when the ignition key is ON.
lighted indicator. Auxiliary hydraulic override – if pressed, the light
9. Parking brake state (ON/OFF) – lighted indicator. next to the switch will turn on for thirty seconds.
10. Engine preheat state (ON/OFF) – lighted Within that period of time, an operator may leave the
indicator. seat without interruption to attachment hydraulic flow.
This feature is turned off or reset while the operator is
11. Battery voltage (over/under) – displayed in place in the seat and (1) the operator again pushes the
of engine hours when out of limits high/low. button during the thirty seconds (2) automatically
12. Engine hours (accumulated to tenth hour) – after thirty seconds or (3) leaves to operate the
character display. attachment and then sits back down in the seat at
13. Fuel level – eight element vertical bar graph. some later time. When the operator returns to the
seat after using an implement for an extended period
Controlled Functions: of time, the brake button must be pushed again to
1. Hydraulic interlock solenoid output – inhibits enable the loader hydraulic system and turn off the
boom/bucket movement when operator out of brake. The override feature is primarily used to
seat or the seat restraint bar is in the raised support attachments such as a backhoe or other
position. out-of-cab operated implements.
2. Hydraulic brake output – prevents loader motion
when the operator is out of the seat, or the seat
restraint bar is in the raised position.
3. Grid heat output (if equipped) – applies power to
the grid heater relay for an interval of time
determined by the temperature of the engine
coolant each time the ignition key is turned from
off to on.
4. Hydraulic auxiliary override – enables a
continuous hydraulic flow to attachments when
an operator leaves the seat to operate an
attachment. If not pushed, provides a safety
interlock during operator entry/exit of the loader.
Additionally, a four push-button operator selector
area located on the EIC provides the following
functions during normal operation:

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 4001-101
Restraint System: The EIC contains logic to ensure 3. Road light: Used to view in succession all of the
operator safety. The EIC continually monitors the values that an item can have. When changing
seat switch and the seat restraint bar switch. If, engine hours, this button increments a flashing
during operation, any of these restraint devices digit value in a circular manner from 0 – 9.
indicates to the EIC that the operator has left the seat 4. Work light: Used to navigate to the next menu
or is about to leave the seat, the EIC will inhibit item. When changing engine hours, this button
hydraulic flow to the boom and bucket and will set the causes the flashing emphasis to move to the
brake. next digit to the right.
Additionally, if the operator has not pressed the
auxiliary hydraulic override push button, flow will be 5. Auxiliary override: This button functions as an
halted to attachments via hydraulic solenoid interlock unconditional setup exit without save from any
or automatic engine shut down provided that the location in the menu. When this button is
auxiliary control is displaced from neutral. pushed, the EIC will turn off. If the operator is in
the seat, the EIC will immediately power up
To prevent annoying attachment flow interruption normally. None of any changed information will
and hydraulic brake activation due to be saved unless that information was first saved
operator-induced seat switch bounce, the EIC using the parking brake button and then verified.
implements a short seat switch time delay prior to
6. To Exit the Setup Menu: (1) Leave the loader.
halting auxiliary flow.
After three seconds the EIC will automatically
The EIC will power up when an operator sits in the
power down, (2) place the ignition key in either
seat. This enables viewing of fuel level and engine
the ACC or the ON position or (3) push and
hours without use of the ignition key. If the operator is
release the auxiliary override button.
in the seat for more than thirty seconds and the
ignition key is not turned on, the EIC will turn itself
off.
EIC Special Functions (Setup Menu):
Special machine setup features are available via the
operator push button selector area. The EIC will
display the word “SETUP” as a first menu item visual
“anchor” message.The choices available are:
A. (1) Select engine type: (for correct cold engine
preheat profile)
B. (2) Select brake type: hydraulic or no brake
C. (3) Display EIC software revision level.
D. (5) Modify engine hours: (coded entry
required).

Push Button Definitions:

1. Any button: Any button may be depressed and
held for six seconds to enter the setup mode.
The seat must be unoccupied and the ignition
key off during this time, but the operator may sit
in the seat after the setup mode is entered.
2. Parking brake: Provides for editing the values
that a setup menu item (engine type, brake type,
engine hours) can have. When a value has been
changed, this button is also used to save the
value in memory. Verification of the saved value
is automatic. The display will blank and go dark.
Then, after a short delay time, the value will be
retrieved from memory and shown again in the
display. After this visual verification, the word
“SETUP” will again appear in the display.

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4001-102

Special Feature Choices: Changing Engine Hours:

1. Display/select engine type. ATTENTION: You must contact your CNH
2. Display/change brake type. Technical Services Adviser to obtain the UNLOCK
CODE before the Engine Hourmeter can be
3. Display/change engine hours are the only values changed.
that may be modified.
To change engine hours (item 4), press and release
NOTE: For the following three descriptions, it is the work light push button four times until the word
assumed that the operator has already placed the “HOUR” is displayed. Then, push and release the
instrument cluster in the SETUP mode and is sitting park brake push button. The word “UNLOCK” will be
in the seat. The word “SETUP” appears in the text displayed for two seconds to prompt that an
display. unlocking code must be entered to change engine
hours. After the two second delay, the display will
Detailed Description of Setup prompt for the entry of a four-digit code. The leftmost
Items: digit after the prompt “>” will flash, indicating a digit
that can be changed. Using the road light push
button to change the digit value and the work light
Selecting an Engine Preheat Profile:
push button to select the next digit, enter the
To select an engine preheat profile (item 1), press unlocking code.
and release the work light push button one time. The Push and release the park brake push button to
word “ENGIN” will be displayed. Then, push and accept this unlocking code. Currently stored engine
release the park brake push button. The engine type hour value will be retrieved and displayed and the
“CASE” (for Case brand) or “ISM” will be displayed leftmost digit will flash. Using the same technique
depending on the profile currently stored in the EIC. outlined above, enter the desired engine hour value.
Push and release the road light push button to switch Push and release the park brake push button to store
between the engine types. When the desired engine the new engine hour value. After visual verification,
type is displayed, push and release the park brake the word “SETUP” will again appear in the display.
push button to store the new selection. After visual Exit the Setup Menu using one of the three methods
verification, the word “SETUP” will again appear in described above.
the display.

Changing Brake Type:

To select a brake type (item 2), press and release the
work light push button two times. The word “BRAKE”
will be displayed. Then, push and release the park
brake push button. The brake type “HYDRL” (for
hydraulic) “NOBRK” (for no brake – to adjust drive
neutral) or “MANUL” (for manual) will be displayed
depending on the type currently stored in the EIC.
Push and release the road light push button to switch
between the brake types. When the desired type is
displayed, push and release the park brake push
button to store the new selection. After visual
verification, the word “SETUP” will again appear in
the display.

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 4001-103

TROUBLESHOOTING
ELECTRONIC INSTRUMENT CLUSTER (EIC)
PROBLEM POSSIBLE CAUSE CORRECTION

EIC board will not light up when Faulty seat switch. Replace switch
operator sits in the seat.

No battery voltage to seat switch. Blown 5 amp fuse electronic bat-

tery in engine panel, replace fuse.
Open in power wire from 5 amp
fuse from supply, check and/or
replace battery.
No battery voltage to 5 amp fuse
from supply, check and/or replace
battery.

Blown 5 amp fuse (electronic bat-

Replace fuse.
tery) in engine panel.

No battery voltage from seat switch Open in power wire from seat
to EIC board. switch to EIC board, repair open
wire.
Poor or no connection at EIC
board, repair connection.

Battery voltage from seat switch to If battery voltage from seat to

EIC board. board is OK, replace the EIC.

EIC backlighting is dim. Brightness variations due to produc- None -- overlay decal material
tion differences between models variations cause differences in
and/or EIC board changes. brightness.

Backlights dim when the loader None -- EIC board circuitry auto-
worklights are activated. matically dims the backlighting
when then worklights are on, to
reduce the glare at night.

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4001-104

PROBLEM POSSIBLE CAUSE CORRECTION

EIC will not read correct Engine Incorrect engine configuration. Correct the engine configuration.
RPM, and varies more than ± 50
RPM.

No AC voltage at tachometer termi- Repair alternator.

nal at alternator.

Loose or corroded connection at

Repair connection.
tachometer terminal at alternator.

No AC voltage at EIC board from Open in wire from alternator to

alternator. EIC board, repair connection.

AC voltage from alternator to EIC Repair loose or corroded connec-

board. tion at EIC board.

Wire connection from alternator to If OK, replace EIC.

EIC board.

EIC will not unlock boom and Seat restraint bar not in operating Lower the restraint bar to the oper-
bucket spool locks. position (down). ating position (down).

No battery voltage from seat Open in power wire from seat

restraint bar switch to EIC. restraint bar switch, repair open.

No battery voltage from EIC to spool Open in power wire from EIC to
lock solenoids. solenoids, repair open.

Battery voltage to lock solenoids. If OK, check inoperative sole-

noids, check solenoid coils and
repair or replace.

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 4001-105

PROBLEM POSSIBLE CAUSE CORRECTION

Engine will not start and/or run. Incorrect Engine configuration. Correct configuration.
(EIC)

No battery voltage to start relay. Open in power wire from key

switch “START” to relay, or
through seat/seat restraint bar cir-
cuits to relay, repair open.

No battery voltage from EIC to fuel Open in power wire from EIC to
solenoid. fuel solenoid, repair open.

Inoperative start interlock relay. Repair or replace.

Fuel solenoid inoperative. Repair or replace.

Inoperative Engine preheat system. Incorrect Engine configuration,

correct configuration.

No power to Engine preheater. Manifold heater preheat relay or

wire open, repair or replace.

Inoperative manifold heater. Replace manifold heater.

Engine turns over, but will not Check 7.5 amp fuse in cab fuse
No power to fuel solenoid.
start. block.
Check interlock fuel solenoid
relay.
If equipped with auxiliary override
switch, make sure switch is in neu-
tral position.

No power to starter, no power to key Check key switch, seat switch,

Engine will not turn over.
switch. start interlock relay, battery.
Check 5 amp fuse in engine fuse
panel.
Check 15 amp fuse in engine fuse
panel.

Engine will start and run but boom No power to control valve lockout Check for power at spool lockout
and bucket will not move. solenoids. solenoids.
Check 15 amp fuse in cab fuse
block.
Replace EIC.

EIC will not read monitored cir-

Incorrect engine configuration. Correct engine configuration.
cuits.

Open or short in wire from sensor to Repair open/short.

EIC.

Faulty sender or sensor. Repair/replace sender or sensor.

Bur 6-79540 Issued 2-05 Printed in U.S.A.

4001-106
NOTES

Bur 6-79540 Issued 2-05 Printed in U.S.A.

5
 SECTION INDEX

TRACKS

Section Title Section Number

Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001
Drive Sprocket, Idler Wheels, and Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5002

Copyright © 2006 CNH America LLC

All rights reserved.
CNH AMERICA LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 5-2630 Issued March, 2006
 SECTION INDEX

POWER TRAIN

Section Title Section Number

Hydrostatic System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
Removal and Installation of Hydrostatic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6002
Drive Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6003
Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Drive Motors (Eaton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005
Single Speed Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005
Sprockets, Chains, and Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011

Copyright © 2005 CNH America LLC

All rights reserved.
CNH AMERICA LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79080 Issued February, 2005
 6002
Section
6002

REMOVAL AND INSTALLATION OF

HYDROSTATIC COMPONENTS

CNH AMERICA LLC

700 State Street Copyright © 2005 CNH America LLC
Racine, WI 53404 U.S.A. Printed in U.S.A.
Bur 6-79531 Issued February, 2005 (Revised March 2006)
6002-2

TABLE OF CONTENTS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TANDEM (HYDROSTATIC) PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
410 HYDRAULIC (DRIVE) MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
420 HYDRAULIC (DRIVE) MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
420CT Final Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Bur 6-79531 Revised 3-06 Printed in U.S.A.

 6002-3

TORQUE SPECIFICATIONS
Tandem Pump to Bracket Mounting Bolts
(Apply Locktite 243 to the Threads)...................................................................110 to 122 Nm (80 to 90 pound-feet)
Tandem Pump Mounting Bracket to Chassis Mounting Bolts
(Apply Locktite 243 to the Threads).......................................................................54 to 60 Nm (40 to 44 pound-feet)
410 Hydraulic Drive Motor Mounting Bolts ...................................... 56 Nm (40 pound-feet) plus Turn Additional 65°
420 Hydraulic Drive Motor Mounting Bolts
(Apply Locktite 243 to the Threads)............................................... 122 Nm (90 pound-feet) plus Turn Additional 60°
420CT Final Drive Motor Mounting Bolts
Initial Torque (Tighten in star Pattern) ...............................................................67 to 163 Nm (50 to 120 pound-feet)
Final Torque (Tighten in star Pattern)............................................................183 to 205 Nm (136 to 153 pound-feet)

Bur 6-79531 Revised 3-06 Printed in U.S.A.

6002-4

TANDEM (HYDROSTATIC) PUMP

Removal STEP 7
Disconnect all the electrical connections from the
STEP 1 tandem pump.
Remove the cap from the hydraulic reservoir.
STEP 8
STEP 2 Remove the nuts, washers, and control linkages from
Connect a vacuum pump to the hydraulic reservoir. the tandem pump.

STEP 3 STEP 9
Start the vacuum pump. Connect acceptable lifting equipment to the tandem
pump.
STEP 4
STEP 10

BD05C001
BD05C001
Tag and disconnect all hoses from the tandem pump. Loosen and remove the set screw in the pump drive
Install plugs in the hoses and caps on the fittings. joint.

STEP 5 STEP 11

BD05A085
BD05C001
Remove the access plate for the gear pump. Tag and
Remove the bolts and washers from the tandem
disconnect all hoses from the gear pump. Install
pump mounting flange.
plugs in the hoses and caps on the fittings.

STEP 6
Stop the vacuum pump.

Bur 6-79531 Revised 3-06 Printed in U.S.A.

 6002-5
STEP 12 Installation
STEP 1
Connect acceptable lifting equipment to the tandem
pump. Use the lifting equipment and move the
tandem pump into the mounting location.

STEP 2

BD05C001

Loosen and remove the mounting bolts from the front

tandem pump mounting bracket.

STEP 13
Move the tandem pump away from the engine and
disengage the pump drive shaft from the pump drive
joint. BD05C001

Move the tandem pump towards the engine. Engage

STEP 14 the splines of the pump drive joint with the splines on
Remove the tandem pump from the machine. the pump drive shaft.

STEP 3

BD05C001

Apply Loctite No. 243 to the threads of the front

tandem pump bracket mounting bolts and install the
mounting bolts. Tighten the mounting bolts to a
torque of 54 to 60 Nm (40 to 44 pound-feet).

Bur 6-79531 Revised 3-06 Printed in U.S.A.

6002-6
STEP 4 STEP 10

BD05C001 BD05A085

Apply Loctite No. 243 to the threads and install the 4 Remove the plugs from the hoses and caps from the
tandem pump mounting bolts and washers and nuts fittings. Connect and tighten all hoses to the fittings
into the tandem pump mounting bracket. Tighten the on the gear pump. Install the access plate for the
mounting bolts to a torque of 54 to 60 Nm (40 to 44 gear pump. Install and tighten the mounting bolts for
pound-feet). the access cover.

STEP 5 STEP 11
Install and tighten the set screw in the pump drive Stop the vacuum pump. Disconnect the vacuum
joint. pump from the hydraulic reservoir. Install the cap on
the reservoir.
STEP 6
Connect all the electrical connections to the tandem STEP 12
pump Clean up any hydraulic fluid from equipment or floor.

STEP 7 STEP 13
Install the control linkages washers, and nuts to the Start and run the engine at low idle for 2 to 5 minutes
tandem pump. and check for any leaks.

STEP 8 STEP 14
Start the vacuum pump. Stop the engine.

STEP 9 STEP 15
Check the level of the oil in the hydraulic reservoir.
Add hydraulic oil as required. See Section 1001 for
the correct hydraulic oil specifications.

STEP 16
Install the cap on the hydraulic reservoir.

BD05C001

Remove the caps from the fittings and plugs from the
hoses. Connect and tighten all of the hoses to the
fittings on the tandem pump.

Bur 6-79531 Revised 3-06 Printed in U.S.A.

 6002-7

3
1

BS04N063
1. BOLTS 3. BELL HOUSING
2. PUMP DRIVE JOINT 4. FLYWHEEL
DRIVE COUPLING INSTALLATION

Bur 6-79531 Revised 3-06 Printed in U.S.A.

6002-8

410 HYDRAULIC (DRIVE) MOTOR

Removal STEP 4
Remove the cap from the hydraulic reservoir.
NOTE: Photos may not be the same as the machine
you are repairing, the procedure is the same.
STEP 5
NOTE: It may be necessary to disconnect hydraulic Connect a vacuum pump to the hydraulic reservoir.
hoses from the tandem pump, or remove the tandem
pump from the machine, to remove the hydraulic
STEP 6
drive motors from the machine. See page 4 for the
procedure to remove the tandem pump from the Start the vacuum pump.
machine.
STEP 7
STEP 1

1 2

BD05A087

BD01C103
Tag and disconnect all of the hydraulic hoses and
Remove the bolts (1) and washers from the chain hydraulic lines from the drive motor / brake
tank cover (2). Remove the chain tank cover (2) from assembly. Install plugs in the hoses and caps on the
the machine. fittings.

STEP 2 STEP 8
Stop the vacuum pump.

1 3 STEP 9
1 Attach acceptable lifting equipment to the drive
motor.

2 STEP 10

BD01F305

Loosen the flange nuts (3) on the front and rear axle
housings. Slide the axle housings towards the drive
sprocket (2) to allow slack in the drive chains.
Remove the drive chains (1) from the drive sprocket
(2).

STEP 3 BD05A086
Place a shop towel under the hydraulic drive motor / Loosen and remove the mounting bolts from the
brake assembly. drive motor mounting flange which fasten the drive
motor / brake assembly to the chassis. Remove the
drive motor / brake assembly from the chassis.
Bur 6-79531 Revised 3-06 Printed in U.S.A.
 6002-9

Installation STEP 15
If the tandem pump was removed, install the tandem
STEP 11 pump.
Use acceptable lifting equipment and install the drive
motor / brake assembly into the chassis mounting STEP 16
location. Stop the vacuum pump. Disconnect the vacuum
pump from the reservoir. Install the cap on the
STEP 12 hydraulic reservoir.

STEP 17

1
1

BD05A086

Install the mounting bolts and nuts into the drive

motor mounting flange. Tighten the nuts to a torque BD01F305

of 122 Nm (90 pound-feet) plus turn additional 60° . Install the drive chains (1) onto the drive sprocket (2).

STEP 13 STEP 18
Start the vacuum pump. See Section 6007 for the procedure to adjust the
drive chain tension.
STEP 14
STEP 19
Adjust the drive chain tension.

STEP 20

BDO5A087

Remove the caps from the fittings and plugs from the
hoses. Install and tighten all of the hoses and
hydraulic lines on the drive motor.
BD01C258

Remove the old sealant and apply new RTV sealant

between the gasket, cover, and the chassis. Install
the chain tank cover and the bolts onto the chassis.
Tighten the bolts to a torque of 125 to 150 Nm (93 to
112 pound-feet).

Bur 6-79531 Revised 3-06 Printed in U.S.A.

6002-10
STEP 21 STEP 22
Clean up any hydraulic oil from the equipment or the
floor.

STEP 23
Start and run the engine at low idle for 2 to 5 minutes
and check for any leaks.

STEP 24
Disengage the park brake and move the machine in
order to remove any air from the hydrostatic system.

BD01C268 STEP 25
If the wheels were removed, install the wheels and Stop the engine.
the wheel nuts.
For machines equipped with Stamped Center STEP 26
Wheels with tapered type lug nuts, tighten wheel nuts
Check the level of the oil in the hydraulic reservoir.
to a torque of 135 to 163 Nm (100 to 120
Add hydraulic oil as required. See Section 1001 for
pound-feet).
the correct hydraulic oil specifications.
For machines equipped with Solid Center Wheels
with flange type lug nuts, tighten wheel nuts to a
torque of 224 to 265 Nm (165 to 195 pound-feet). STEP 27
Install the cap on the hydraulic reservoir.

Bur 6-79531 Revised 3-06 Printed in U.S.A.

 6002-11

1
2

4
3

BS05C069
1. HYDROSTATIC PUMP 4. GEAR PUMP
2. DRIVE MOTOR 5. FILTER ASSEMBLY
3. BRAKE VALVE
410 HYDROSTATIC DRIVE SYSTEM

Bur 6-79531 Revised 3-06 Printed in U.S.A.

6002-12

420 HYDRAULIC (DRIVE) MOTOR

Removal STEP 4
Remove the cap from the hydraulic reservoir.
NOTE: Photos may not be the same as the machine
you are repairing, the procedure is the same.
STEP 5
NOTE: It may be necessary to disconnect hydraulic Connect a vacuum pump to the hydraulic reservoir.
hoses from the tandem pump, or remove the tandem
pump from the machine, to remove the hydraulic STEP 6
drive motors from the machine. See page 4 for the Start the vacuum pump.
procedure to remove the tandem pump from the
machine. STEP 7
STEP 1

1 2

BS05C072
Tag and disconnect all of the hydraulic hoses and
BD01C103 hydraulic lines from the drive motor / brake
Remove the bolts (1) and washers from the chain assembly. Install plugs in the hoses and caps on the
tank cover (2). Remove the chain tank cover (2) from fittings.
the machine.
STEP 8
STEP 2 Stop the vacuum pump.

STEP 9
1 3 Attach acceptable lifting equipment to the drive
1 motor.

STEP 10
2

BD01F305

Loosen the flange nuts (3) on the front and rear axle
housings. Slide the axle housings towards the drive
sprocket (2) to allow slack in the drive chains.
Remove the drive chains (1) from the drive sprocket
(2).
BS05C072
STEP 3 From inside the chain tank, loosen and remove the
Place a shop towel under the hydraulic drive motor / mounting bolts from the drive motor mounting flange
brake assembly. which fasten the drive motor / brake assembly to the
chassis. Remove the drive motor / brake assembly
from the chassis.

Bur 6-79531 Revised 3-06 Printed in U.S.A.

 6002-13

Installation STEP 15
If the tandem pump was removed, install the tandem
STEP 11 pump.
Use acceptable lifting equipment and install the drive
motor / brake assembly into the chassis mounting STEP 16
location. Stop the vacuum pump. Disconnect the vacuum
pump from the reservoir. Install the cap on the
STEP 12 hydraulic reservoir.

STEP 17

1
1

BS05C072

Install the mounting bolts and nuts inside the chain

tank into the drive motor mounting flange. Tighten BD01F305

the bolts to a torque of 122 Nm (90 pound-feet) plus Install the drive chains (1) onto the drive sprocket (2).
turn additional 60° .
STEP 18
STEP 13 See Section 6007 for the procedure to adjust the
Start the vacuum pump. drive chain tension.

STEP 14 STEP 19
Adjust the drive chain tension.

STEP 20

BS05C072

Remove the caps from the fittings and plugs from the
hoses. Install and tighten all of the hoses and
hydraulic lines on the drive motor. BD01C258

Remove the old sealant and apply new RTV sealant

between the gasket, cover, and the chassis. Install
the chain tank cover and the bolts onto the chassis.
Tighten the bolts to a torque of 125 to 150 Nm (93 to
112 pound-feet).

Bur 6-79531 Revised 3-06 Printed in U.S.A.

6002-14
STEP 21 STEP 22
Clean up any hydraulic oil from the equipment or the
floor.

STEP 23
Start and run the engine at low idle for 2 to 5 minutes
and check for any leaks.

STEP 24
Disengage the park brake and move the machine in
order to remove any air from the hydrostatic system.

BD01C268 STEP 25
If the wheels were removed, install the wheels and Stop the engine.
the wheel nuts.
For machines equipped with Stamped Center STEP 26
Wheels with tapered type lug nuts, tighten wheel nuts
Check the level of the oil in the hydraulic reservoir.
to a torque of 135 to 163 Nm (100 to 120
Add hydraulic oil as required. See Section 1001 for
pound-feet).
the correct hydraulic oil specifications.
For machines equipped with Solid Center Wheels
with flange type lug nuts, tighten wheel nuts to a
torque of 224 to 265 Nm (165 to 195 pound-feet). STEP 27
Install the cap on the hydraulic reservoir.

Bur 6-79531 Revised 3-06 Printed in U.S.A.

 6002-15

4 3

BS05C071
1. HYDROSTATIC PUMP 4. GEAR PUMP
2. DRIVE MOTOR 5. FILTER ASSEMBLY
3. BRAKE VALVE
420 HYDROSTATIC DRIVE SYSTEM

Bur 6-79531 Revised 3-06 Printed in U.S.A.

6002-16

420CT FINAL DRIVE MOTOR

Removal STEP 5
Stop the vacuum pump.
STEP 1
Refer to Section 5001 Tracks and follow the STEP 6
procedure to remove the tracks from the machine. Loosen and remove all the connectors from the ports
on the drive motor to allow room to slide the drive
STEP 2 motor out of the main frame. Install clean plastic
plugs into the ports to avoid contamination.

STEP 7

BS05C139_1

Loosen and remove the upper and lower mounting

bolts (1) which fasten the rear cover (2) to the main
frame (3). BS05C164

Make a reference mark on the drive motor (2) and

STEP 3 the main frame (3) to be used fro alignment of the
Connect a vacuum pump to the reservoir and apply drive motor during the installation procedure.
vacuum to the reservoir.
NOTE: Clean the hydraulic lines, fittings, and
STEP 8
connectors and the area around the motor
connections to prevent dirt from entering the
hydraulic system when the lines are disconnected
from the motor.

STEP 4

BS05C164_2

Loosen and remove the mounting bolts (1) which

fasten the drive motor (2) to the main frame (3). Slide
the drive motor (2) out of the main frame (3).

BC05C164_1

Loosen and remove all of the hydraulic lines that are

connected to the drive motor. Place plugs and caps
on all of the hydraulic lines and fittings.

Bur 6-79531 Revised 3-06 Printed in U.S.A.

 6002-17

Installation STEP 11

STEP 9

BS05C156_1

Tighten the mounting bolts to a initial torque of 67 to

BS05C164_3
163 Nm (50 to 120 pound-feet) using the star
Slide the drive motor (1) into the main frame (2) tightening sequence shown. After the initial torque is
mounting location. If the same motor is being complete, tighten the mounting bolts to a final torque
installed, use the reference marks made during of 183 to 205 Nm (136 to 153 pound-feet) using the
removal and align the drive motor in the main frame. star tightening sequence shown.
If a new motor is being installed, transfer the
reference mark from the old motor to the same STEP 12
location on the new motor and align the drive motor
in the main frame.

STEP 10

BS05C164_1

Remove the plastic plugs from the motor ports (1).

Install the connectors into the motor ports (1) and
tighten the connectors.
BS05C164_4

Install the mounting bolts (1) into the main frame.

Bur 6-79531 Revised 3-06 Printed in U.S.A.

6002-18
STEP 13 STEP 18
Start the vacuum pump. Remove the caps from lines Stop the engine.
and connect the lines to the drive motor. Tighten all
of the hydraulic lines. STEP 19

STEP 14
Stop the vacuum pump and remove the vacuum
pump from the reservoir.

STEP 15
Refer to Section 5001 Tracks and follow the
procedure to install the tracks on the machine.

STEP 16
Refer to Section 5001 Tracks and follow the
procedure for Adjusting the Rubber Track Tension BS05C139_1
and adjust the tension of the track. Install the rear cover (2) onto the main frame (3).
Install the upper and lower mounting bolts (1) into the
STEP 17 rear cover (2). Tighten the mounting bolts (1).
Start and run the engine at low idle for 2 to 5 minutes
and check for any leaks. STEP 20
Check the oil level in the hydraulic reservoir and add
hydraulic oil as required.

Bur 6-79531 Revised 3-06 Printed in U.S.A.

 6002-19

BS06E237
1. LEFT FINAL DRIVE MOTOR 3. BRAKE VALVE
2. RIGHT FINAL DRIVE MOTOR 4. FILTER ASSEMBLY
420CT HYDROSTATIC DRIVE SYSTEM

Bur 6-79531 Revised 3-06 Printed in U.S.A.

6002-20
NOTES

Bur 6-79531 Revised 3-06 Printed in U.S.A.

 Section
6003

6003
DRIVE COUPLER

CNH AMERICA LLC Copyright © 2005 CNH America LLC

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79120 Issued February, 2005
6003-2

TABLE OF CONTENTS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DRIVE COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Bur 6-79120 Issued 2-05 Printed in U.S.A.

 6003-3

TORQUE SPECIFICATIONS
Bolts for Pump Drive Joint ...................................................................................94 to 106 Nm (69 to 78 pound-feet)

Bur 6-79120 Issued 2-05 Printed in U.S.A.

6003-4

DRIVE COUPLER

Disassembly Inspection
1. Tilt the ROPS canopy forward according to the 1. Inspect the pump drive joint (2) for cracks or any
instructions in Section 9004. other damage. Inspect the splines on the pump
drive joint (2) for wear or any other damage. Use
2. Loosen and remove the bolts (1) and washers new parts as required.
from the pump drive joint (2).
3. Remove the pump drive joint (2) from the engine.
4. Slide the pump drive joint (2) off of the pump
drive shaft and remove the pump drive joint (2)
from the pump shaft.

Bur 6-79120 Issued 2-05 Printed in U.S.A.

 6003-5

3 1
1
BS04N063

1. BOLTS 3. BELL HOUSING

2. PUMP DRIVE JOINT 4. FLYWHEEL
EXPLODED VIEW OF DRIVE COUPLER

Bur 6-79120 Issued 2-05 Printed in U.S.A.

6003-6

Assembly
1. Apply Molycote GN tp the pump drive joint (2)
splines. Engage the pump drive joint (2) splines
onto the splines of the pump shaft. Slide the
pump drive joint (2) onto the pump drive shaft.
2. Install the pump drive joint (2) onto the flywheel
(4). Install the mounting bolts (1) into the pump
drive joint (2). Tighten the bolts (1) to a torque of
94 to 106 Nm (69 to 78 pound-feet).

3. Lower the ROPS canopy according to the

instructions in Section 9004.
4. Start and run the engine at low idle and check for
oil leaks.
5. Stop the engine and check the oil level in the
hydraulic reservoir. If the level is low, add only
the specified oil to the hydraulic reservoir. See
Section 1001.

Bur 6-79120 Issued 2-05 Printed in U.S.A.

 Section
6005

DRIVE MOTORS (EATON)

WITH SPRING APPLIED - HYDRAULIC RELEASE

6005
BRAKES

CNH AMERICA LLC. Copyright © 2005 CNH America LLC

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79020 Issued February, 2005
6005-2

TABLE OF CONTENTS
DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Bur 6-79020 Issued 2-05 Printed in U.S.A.

 6005-3

DRIVE MOTOR

Disassembly STEP 4
NOTE: The following photos may not match your
machine, the procedure is the same.

STEP 1

BD01M052

Remove the end cover.

STEP 5
BD01M049

Mark all points of separation.

STEP 2

BD01M053

Remove the dash pot and spring from the valve

plate.

BD01M050 STEP 6
Loosen the bolts on the end cover.

STEP 3
Set the motor on blocks or in a vise with soft jaws.
Then remove the bolts.

BD01M054

Remove the valve plate.

Bur 6-79020 Issued 2-05 Printed in U.S.A.

6005-4
STEP 7 STEP 10

BD01M055

Remove the geroter assembly. Be careful not to BD01M058

loose the two small check balls in the bottom of the Remove the drive shaft.
geroter star.
STEP 11
STEP 8

BD01M059

BD01M056 Remove and discard the seal and back-up ring.

Remove the outer thrust plate.
STEP 12
STEP 9

BD01M060

Remove the O-ring from the flange.

BD01M057

Remove the inner thrust plate.

Bur 6-79020 Issued 2-05 Printed in U.S.A.

 6005-5
STEP 13 STEP 16

BD01M061 BD01M066

Remove the seal from the flange. Remove the inner O-ring from the valve plate.

STEP 14 STEP 17

BD01M068
BD01M067

Remove the seal from the geroter housing. Remove the seal from the outer thrust plate.

STEP 15 STEP 18

BD01M062
BD01M065

Remove the outer seal from the valve plate. Remove the plug from the end cover.

Bur 6-79020 Issued 2-05 Printed in U.S.A.

6005-6
STEP 19 STEP 21

2
3
BD01M063
4
Remove the dash pot, spring, and poppet from the BS01M204

cover. 1. PLUG 2. SPRING 3. SHIM(S) 4. POPPET 5. O-RING

Remove the plug (1), spring (2), shim(s) (3), and
STEP 20 poppet (4) from the end cover.
NOTE: Refer to illustration on page 7.

BD01M064

Turn the cover on its side and remove the poppet

and shuttle piston.

Bur 6-79020 Issued 2-05 Printed in U.S.A.

 6005-7

24
28
25
27 3 28
26
4
5
6
7 6
5
2 4
18
8
17
9
21
20 10
12
19 16 22
15

21

11 13
14

23

BS01M202
1. BOLT 8. VALVE PLATE 15. O-RING 22. FLANGE
2. END COVER 9. GEROTER ASSEMBLY 16. SEAL 23. SEAL
3. PLUG 10. OUTER THRUST PLATE 17. SEAL 24. PLUG
4. DASH POT 11. INNER THRUST PLATE 18. SEAL 25. SPRING
5. SPRING 12. DRIVE SHAFT 19. O-RING 26. SHIM
6. POPPET 13. BACKUP RING 20. SEAL 27. POPPET
7. SHUTTLE PISTON 14. O-RING 21. CHECK BALL 28. O-RING
DRIVE MOTOR

Bur 6-79020 Issued 2-05 Printed in U.S.A.

6005-8

Assembly STEP 25

STEP 22

BD01M068

Install a new seal onto the outer thrust plate.

BD01M061

Install the outer square cut seal on the flange. STEP 26

STEP 23

BD01M057

Install the inner thrust plate on the flange.

BD01M060

Install a new O-ring on the flange. STEP 27

STEP 24

BD01M056

Install the outer thrust plate on the flange.

BD01M059

Install the O-ring and backup ring on the flange with

the backup ring on top.

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 6005-9
STEP 28 STEP 31

BD01M058 BD01M065

Install the drive shaft into the output shaft. Install a new seal onto the valve plate.

STEP 29 STEP 32

BD01M067 BD01M066

Install a new seal onto the geroter housing. Install a new O-ring onto the valve plate.

STEP 30 STEP 33

BD01M055 BD01M054

Install the geroter assembly onto the shaft. Make Install the valve plate.
sure the two small check balls do not fall out.

Bur 6-79020 Issued 2-05 Printed in U.S.A.

6005-10
STEP 34 STEP 37

BD01M064 BD01M063

Install the shuttle piston and poppet into the end Install the poppet, spring, dash pot, and plug into the
cover. Use grease to hold them in place. end cover.

STEP 35 STEP 38
Install the spring and dash pot into the cover. Use
grease to hold them in place.

STEP 36

BD01M051

Install the plug on the cover.

STEP 39
BD01M050

Install the end cover and secure it with the bolts.

Torque bolts to 108 Nm (80 pound-feet).
1

2
3
4
BS01M204

1. PLUG 2. SPRING 3. SHIM(S) 4. POPPET 5. O-RING

Install the poppet (4), spring (2), shim(s) (3), and plug
(1) into the end cover.
NOTE: Refer to illustration on page 7.

Bur 6-79020 Issued 2-05 Printed in U.S.A.

 SECTION INDEX

BRAKES

Section Title Section Number

Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7002
410 Brakes - Spring Applied - Hydraulic Release . . . . . . . . . . . (Refer to Section 6005 - Single Speed Drive Motor)
420 Brakes - Spring Applied - Hydraulic Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004

Copyright © 2005 CNH America LLC

All rights reserved.
CNH AMERICA LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79090 Issued February, 2005
 7002
Section
7002

REMOVAL AND INSTALLATION OF

PARK BRAKE COMPONENTS

CNH AMERICA LLC Copyright © 2006 CNH America LLC

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79571 February, 2005 (Revised March, 2006)
7002-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
410 PARK BRAKES (SPRING APPLIED - HYDRAULIC RELEASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
420 PARK BRAKES (SPRING APPLIED - HYDRAULIC RELEASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Bur 6-79571 Revised 3-06 Printed in U.S.A.

 7002-3

SPECIFICATIONS
410 Brake System
Type .................................................................................................Wet Disk, Spring Applied, Hydraulic Release
Release Pressure - Maximum - Fully Disengaged ..................... 1100 to 1500 kPa (11 to 15 bar) (160 to 217 psi)
420 Brake System
Type .................................................................................................Wet Disk, Spring Applied, Hydraulic Release
Release Pressure - Maximum - Fully Disengaged ................................................... 2760 kPa (27.6 bar) (400 psi)

Safety Rules
WARNING: Raised equipment or machine movement without an operator can cause injury or death.
! Before you service this machine, do the following:
1. Park the machine on a level surface,
2. Support or lower the equipment (backhoe, blade, boom, bucket, etc.) to the ground (if equipped).
3. If the loader arms are raised for serviceability, remove the attachment prior to raising the loader arms,
then engage the lock pin or strut.
4. Apply the parking brake.
5. Stop the engine.
6. Block the machine (wheels, tracks, etc.) to prevent machine movement.
84-108

Bur 6-79571 Revised 3-06 Printed in U.S.A.

7002-4

410 PARK BRAKES (SPRING APPLIED - HYDRAULIC RELEASE)

Removal Installation
1. Refer to Section 6005 Single Speed Drive Motor 1. Refer to Section 6005 Single Speed Drive Motor
for removal of the park brake components which for installation of the park brake components
are part of the drive motor assembly. Follow the which are part of the drive motor assembly.
steps for removal of the park brake components. Follow the steps for installation of the park brake
components.

Bur 6-79571 Revised 3-06 Printed in U.S.A.

 7002-5

420 PARK BRAKES (SPRING APPLIED - HYDRAULIC RELEASE)

Removal Installation
1. Refer to Section 7004 420 Brakes 1. Refer to Section 7004 420 Brakes
Spring Applied - Hydraulic Release for removal Spring Applied - Hydraulic Release for
of the park brake components which are part of installation of the park brake components which
the drive motor assembly. Follow the steps for are part of the drive motor assembly. Follow the
removal of the park brake components. steps for installation of the park brake
components.

Bur 6-79571 Revised 3-06 Printed in U.S.A.

7002-6

BRAKE SOLENOID VALVE

Removal Installation
1. Place a shop towel under the brake solenoid 1. Install the brake solenoid valve (1) in the chassis
valve(1). mounting location.
2. Remove the cap from the hydraulic reservoir. 2. Install the mounting bolts (4) which fasten the
brake solenoid valve (1) to the chassis. Tighten
3. Connect a vacuum pump to the hydraulic
the mounting bolts (4).
reservoir.
3. Connect the wiring harness (2) to the brake
4. Start the vacuum pump.
solenoid valve (1).
5. Tag and disconnect all of the hoses (3) from the
4. Start the vacuum pump.
fittings on the brake solenoid valve (1).
5. Remove the plugs in the hoses and caps from
6. Install plugs in the hoses and caps on the fittings.
the fittings.
7. Stop the vacuum pump.
6. Connect all of the hoses (3) to the fittings on the
8. Disconnect the wiring harness (2) from the brake brake solenoid valve (1).
solenoid valve (1).
7. Stop the vacuum pump. Disconnect the vacuum
9. Loosen and remove the mounting bolts (4) which pump from the hydraulic reservoir. Install the cap
fasten the brake solenoid valve (1) to the on the hydraulic reservoir.
chassis.
8. Clean up any hydraulic fluid from equipment or
10. Remove the brake solenoid valve (1) from the floor.
chassis mounting location.
9. Start and run the engine at low idle. Engage and
disengage the park brakes several times.
10. Stop the engine.
11. Check for oil leakage.
12. Check the level of the oil in the hydraulic
reservoir. Add oil as required. Install the cap on
the hydraulic reservoir.

Bur 6-79571 Revised 3-06 Printed in U.S.A.

 7002-7

2
1

7 1
3

3
6

BS05C070
1. BRAKE SOLENOID VALVE 5. TO MANIFOLD VALVE
2. WIRING HARNESS 6. RIGHT HAND BRAKE LINE
3. HYDRAULIC HOSE 7. LEFT HAND BRAKE LINE
4. MOUNTING BOLTS
410 BRAKE SOLENOID VALVE INSTALLATION

Bur 6-79571 Revised 3-06 Printed in U.S.A.

7002-8

2
2

3 1

4
5

6
3

BS05B102
1. BRAKE SOLENOID VALVE 5. MANIFOLD VALVE
2. WIRING HARNESS 6. RIGHT HAND BRAKE LINE
3. HYDRAULIC HOSE 7. LEFT HAND BRAKE LINE
4. MOUNTING BOLTS
420 BRAKE SOLENOID VALVE INSTALLATION

Bur 6-79571 Revised 3-06 Printed in U.S.A.

 7002-9

3
2

7
6 5

BS06E238
1. BRAKE SOLENOID VALVE 5. MANIFOLD VALVE
2. WIRING HARNESS 6. RIGHT HAND BRAKE LINE
3. HYDRAULIC HOSE 7. LEFT HAND BRAKE LINE
4. MOUNTING BOLTS
420CT BRAKE SOLENOID VALVE INSTALLATION

Bur 6-79571 Revised 3-06 Printed in U.S.A.

7002-10
NOTES

Bur 6-79571 Revised 3-06 Printed in U.S.A.

 Section
7004

7004
420 BRAKES
SPRING APPLIED - HYDRAULIC RELEASE

CNH AMERICA LLC Copyright © 2005 CNH America LLC

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79580 February, 2005
7004-2

TABLE OF CONTENTS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Bur 6-79580 Issued 2-05 Printed in U.S.A.

 7004-3

DISASSEMBLY
STEP 1 STEP 3

BDOOM166 BD00M167

Make an alignment mark on the sprocket housing, Loosen and remove the four bolts.
friction housing, and the motor flange.
NOTE: Motor flange is under spring load, use
caution while releasing the tension on the press.
STEP 2
STEP 4

BD00M165

Place the brake assembly on a press and apply just

BD00M169
enough tension to hold the brake assembly in
Remove the drive motor from the friction housing.
position.
STEP 5

BD00M170

Remove the friction housing from the sprocket

housing.

Bur 6-79580 Issued 2-05 Printed in U.S.A.

7004-4
STEP 6 STEP 9

BD00M177 BD00M172

Remove and discard the outer O-ring. Remove the seven stator plates and six lining
assemblies.
STEP 7
STEP 10

BD00M178

Remove and discard the inner O-ring. BD00M173

Turn the brake over and remove and discard the snap
STEP 8 ring.

STEP 11

BD00M171

Remove the friction shim(s).

BD00M187

Press the shaft out of the sprocket housing.

NOTE: Opposite end of the shaft will need to be
supported, once the shaft presses through the press
fit area, the shaft will fall freely.

Bur 6-79580 Issued 2-05 Printed in U.S.A.

 7004-5
STEP 12 STEP 15

BD00M188 BD00M180

Remove the bearing cone from the friction housing. Remove the piston.

STEP 13 STEP 16

BD00M176 BD00M185

1. BEARING CONE Remove and discard the outer O-ring from the piston.
It is not necessary to press the bearing cone from the
shaft unless the bearing assembly is to be replaced. STEP 17

STEP 14

BD00M186

Remove and discard the inner O-ring from the piston.

BD00M179

To remove the piston apply compressed air of no

more than 1.0 bar (15 psi) to the hydraulic port of the
sprocket housing.

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7004-6
STEP 18 STEP 20

BD00M181 BD00M183

Remove the disc spring. 1. BEARING CUP

It is not necessary to remove the bearing cup unless
STEP 19 the bearing assembly is to be replaced.

STEP 21

BD00M182

Remove and discard the seal.

BD00M184

1. BEARING CUP
It is not necessary to remove the bearing cup unless
the bearing assembly is to be replaced.

Bur 6-79580 Issued 2-05 Printed in U.S.A.

 7004-7

20
4

24 11 3

20

6 8

21 12
14 15
5
9

22

17 23
16

13
10
2
18
19
1

BS00J128

1. SHAFT 7. STATOR PLATE 13. O-RING 19. BEARING CONE

2. SPROCKET HOUSING 8. LINING ASSEMBLY 14. O-RING 20. BOLT
3. FRICTION HOUSING 9. DISC SPRING 15. O-RING 21. SNAP RING
4. MOTOR FLANGE 10. QUAD SEAL 16. BEARING CUP 22. PORT PLUG
5. PISTON 11. O-RING 17. BEARING CONE 23. SHAFT PLUG
6. FRICTION SHIM 12. O-RING 18. BEARING CUP 24. SHAFT END SEAL
420 BRAKE ILLUSTRATION

Bur 6-79580 Issued 2-05 Printed in U.S.A.

7004-8

ASSEMBLY
STEP 22 STEP 24

BD00M184 BD00M176

1. BEARING CUP 1. BEARING CONE

If the bearing cup (1) was removed, press a new If the bearing cone (1) was removed, press a new
bearing cup into the sprocket housing. bearing cone onto the shaft until it rests against the
shaft flange.
NOTE: Apply 8 896 to 22 240 N (2000 to 5000
pound- force) to press bearing cup into place.
STEP 25
STEP 23

1 1

BD00M189

BD00M183
1. SHAFT PLUG

1. BEARING CUP
If the shaft plug (1) was removed, or if replacing the
If the bearing cup (1) was removed, press a new shaft, press the shaft plug (1) into the shaft 110.8
bearing cup into the sprocket housing. mm +/-..25mm (4.363 +/- 0.010 inch) from the motor
NOTE: Apply 8 896 to 22 240 N (2000 to 5000 flange mounting face. 35 584 N (8000 pound-force)
pound-force) to press bearing cup into place. maximum.

Bur 6-79580 Issued 2-05 Printed in U.S.A.

 7004-9
STEP 26 STEP 28

BD00M182 BD00M197

1. SEAL Install the sprocket housing onto the shaft. Place the
assembly on the press as shown and press the
Lubricate a new seal (1) with clean SAE 10W30 oil.
bearing cone into place.
Install the seal into the groove of the sprocket
housing. NOTE: Make sure when installing the sprocket
housing onto the shaft that you avoid damaging the
STEP 27 seal.

STEP 29
2

1 2
1
3

BD00M188

1. BEARING CONE
2. SPROCKET HOUSING BD00M198
3. PISTON 1. SNAP RING GROOVE
Install the bearing cone (1) into the sprocket housing 2. BEARING CONE
(2). Measure the gap between the bearing cone (2) and
NOTE: This photo is for reference only. The piston is the snap ring groove (1) to determine the appropriate
installed in step 33. size snap ring to install.
IMPORTANT: It is critical that the sharp (non-rolled)
side of the snap ring is opposite of the bearing cone.

Bur 6-79580 Issued 2-05 Printed in U.S.A.

7004-10
STEP 30 STEP 32

BD00M174 BD00M185

Install the snap ring. Lubricate a new outer O-ring with clean SAE 10W30
oil and install in the groove of the piston.
STEP 31
STEP 33

BD00M186

Lubricate a new inner O-ring with clean SAE10W30 BD00M199

oil and install in the groove of the piston. Install the disc spring into the sprocket housing.

Bur 6-79580 Issued 2-05 Printed in U.S.A.

 7004-11
STEP 34 STEP 37

BD00M200 BD00M177

Lubricate the piston bore of the sprocket housing Lubricate the new outer O-ring for the friction housing
with a thin film of SAE 10W30 oil. Insert the piston with clean SAE 10W30 oil. Install a new outer O-ring
into the sprocket housing being careful not to on the nose of the friction housing.
damage the O-rings.
STEP 38
STEP 35

BDOOM170

BD00M201 Install the friction housing onto the sprocket housing.

Press the piston into place using 4 448 N (1000
pound-force) maximum. STEP 39

STEP 36

BD00M204

Place the assembly in a press and press the friction

BD00M178 housing into place, making sure the alignment
Lubricate the new inner O-ring for the friction housing marks, made during disassembly, are aligned.
with clean SAE 10W30 oil. Install a new inner O-ring
in the groove of the friction housing.

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7004-12
STEP 40 STEP 44
Soak the stator plates and the lining assemblies in
clean SAE 10W30 oil before assembly.

STEP 41

BD00M204

Press the friction stack with 11 120 N (2500

pound-force) to completely compress the spring.

BD00M206 STEP 45
Install a stator plate.
1
STEP 42 2

BD00M207

1. FRICTION HOUSING
2. STATOR PLATE
BD00M205

Install a lining assembly. Measure the distance from the top face of the friction
housing (1) to the top stator plate (2).
STEP 43
Repeat steps 41 and 42 until all six lining assemblies
and seven stator plates are installed.

Bur 6-79580 Issued 2-05 Printed in U.S.A.

 7004-13
STEP 46 STEP 49

BDOOM208 BD00M169

1. SHIMS Install the motor flange onto the friction housing,

making sure that the alignment marks made during
If the measurement taken in step 22 is between 7.26 disassembly are aligned.
to 7.75 mm (0.286 to 0.305 inch), it will not be NOTE: Special care is needed to insure the O-ring
necessary to install any shims (1). If the and the seal are not misaligned or damaged.
measurement was more than 7.75 mm (0.305 inch)
install the necessary amount of shim(s) to reach the STEP 50
correct distance.

STEP 47
lubricate O-ring (11) with clean SAE 10W30 oil and
install onto the nose of the motor flange (4). Refer to
illustration on page 7 of this section.

STEP 48
Install a new seal (24) into the seal groove of the
motor flange (4). Refer to illustration on page 7 of this
section.

BDOOM168

Install the four bolts into the motor flange. Tighten the
four bolts to a torque of 298 to 339 Nm (220 to 250
pound-feet).

Bur 6-79580 Issued 2-05 Printed in U.S.A.

7004-14
NOTES

Bur 6-79580 Issued 2-05 Printed in U.S.A.

 SECTION INDEX

HYDRAULICS

Section Title Section Number

Hydraulic System Troubleshooting and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001
Cleaning the Hydraulic System and Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002
Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8003
Gear Pump (Equipment and High Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8004
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8006
Flat Faced Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007
Accumulator for Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8013

Copyright © 2005 CNH America LLC

All rights reserved.
CNH AMERICA LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79100 Issued February, 2005
 8001
Section
8001

HYDRAULIC SYSTEM TROUBLESHOOTING AND

SCHEMATICS

CNH AMERICA LLC Copyright © 2006 CNH America LLC

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79511 Issued February, 2005 (Revised March, 2006)
8001-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PRESSURE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Loader Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TESTING CIRCUIT RELIEF VALVES WITH A HAND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLOWMETER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Test No. 1 - Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Test No. 2 - Loader Circuits and Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 SPOOL LOADER CONTROL VALVE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
METRIC MEASURE CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
U.S. MEASURE CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
410 HYDRAULIC SCHEMATIC FRAME 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
410 HYDRAULIC SCHEMATIC FRAME 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
410 HYDRAULIC SCHEMATIC FRAME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
410 HYDRAULIC SCHEMATIC FRAME 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
410 HYDRAULIC SCHEMATIC FRAME 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
410 HYDRAULIC SCHEMATIC FRAME 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
410 HYDRAULIC SCHEMATIC FRAME 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
420 HYDRAULIC SCHEMATIC FRAME 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
420 HYDRAULIC SCHEMATIC FRAME 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
420 HYDRAULIC SCHEMATIC FRAME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
420 HYDRAULIC SCHEMATIC FRAME 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
420 HYDRAULIC SCHEMATIC FRAME 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
420 HYDRAULIC SCHEMATIC FRAME 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
420 HYDRAULIC SCHEMATIC FRAME 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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 8001-3

SPECIFICATIONS
Hydraulic Pump
Manufacturer ...................................................................................................................................Sauer-Danfoss
Type ................................................................................................................................................................Gear
Displacement Per Revolution ...................................................................................................... 25.4 cc (1.55 in3)
410 Machines
Flow at Engine Rated RPM at 96% Volumetric Efficiency ................................................ 68.3 litres/min (18 gpm)
Flow at Engine Rated RPM at 100% Volumetric Efficiency ........................................... 73.7 litres/min (19.5 gpm)
420/420CT Machines
Flow at Engine Rated RPM at 96% Volumetric Efficiency ............................................. 70.8 litres/min (18.7 gpm)
Flow at Engine Rated RPM at 100% Volumetric Efficiency ........................................... 73.7 litres/min (19.5 gpm)
Loader Control Valve
Manufacturer .................................................................................................................................................Husco
Type .......................................................................... 3 Spool, Open Center, Series Parallel / with Power Beyond
Main Relief Pressure ................................................................ 20 700 ± 345 kPa (207 ± 3.5 bar) (3000 ± 50 psi)
Port Relief Pressure Settings
Port B1 Std. ................................................................................................... 22 995 kPa 230 bar (3335 psi)
Port A2 Std. (Shut Off Plug) (Optional) ................................................................. 25 993 kPa 260 bar (3770 psi)
Port B2 Anti-Cavitation Valve (Optional) ............................................................... 22 995 kPa 230 bar (3335 psi)
Spool Functions
Loader No.1 (Out) .............................................................................................................................................. Up
Loader No.1 (In) .............................................................................................................................................Down
Loader No.1 (Detent) ......................................................................................................................................Float
Bucket No.2 (In) ........................................................................................................................................ Rollback
Bucket No.2 (Out) ......................................................................................................................................... Dump
Auxilliary No. 3 (In) ................................................................................................................................... Auxilliary
Auxilliary No. 3 (Out) ................................................................................................................................ Auxilliary
Return Filter Bypass Pressure ....................................................................................... 345 kPa, 3.4 bar (50 psi)
Cycle Times With Rated Load In Bucket
Loader Raising Time (410 Machines) ................................................................................................. 4.2 seconds
Loader Raising Time (420 Machines) ................................................................................................. 3.6 seconds
Loader Raising Time (420CT Machines)............................................................................................. 4.0 seconds
Loader Lowering Time (Power Down) (410 Machines) .................................................................... 2.55 seconds
Loader Lowering Time (Power Down) (420 Machines) ...................................................................... 2.1 seconds
Loader Lowering Time (Power Down) (420CT Machines) ................................................................. 2.4 seconds
Bucket Dump Time (410 Machines) .................................................................................................... 2.0 seconds
Bucket Dump Time (420 Machines) .................................................................................................... 1.9 seconds
Bucket Dump Time (420CT Machines) ............................................................................................... 1.9 seconds
Rollback Time (Full Dump to Full Rollback) (410/420 Machines) ....................................................... 1.6 seconds
Rollback Time (Full Dump to Full Rollback) (420CT Machines).......................................................... 1.7 seconds
Optional High Flow (420/420CT Machines)
Hydraulic Pump
Manufacturer ...................................................................................................................................Sauer-Danfoss
Type ................................................................................................................................................................Gear
Model ........................................................................................................................................................ Series D
Displacement Per Revolution (420 Machines) ............................................................................ 17.2 cc (1.05 in3)
Displacement Per Revolution (420CT Machines) ....................................................................... 25.4 cc (1.55 in3)
Flow at Engine Rated RPM at 100% Volumetric Efficiency ........................................... 50.0 litres/min (13.2 gpm)
System
System Relief Valve Pressure (420 Machines) ...................................................... 20 690 kPa 207 bar (3001 psi)
System Relief Valve Pressure (420CT Machines) ................................................. 20 670 kPa 207 bar (3000 psi)
Theoretical System
Hydraulic Flow at Rated Speed, 2000 psi and 100% Volumetric Efficiency.................... 124 litres/min (32.7 gpm)
Measured Flow at 2000 RPM and Maximum Flow....................................................... 113.5 litres/min (30.0 gpm)

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8001-4

SPECIAL TOOLS

B785789M B877895
OEM-1239 (CAS-10280) FLOWMETER CAS-100900 HAND PUMP

B797157M B009638M
CAS-1808 FLOWMETER FITTING KIT CAS-1804 PRESSURE TEST FITTING KIT

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 8001-5

PRESSURE CHECKS

Loader Main Relief 3. Use a pressure gauge with a capacity of at least

276 bar (4000 psi). Connect the pressure gauge
NOTE: Flat face couplers are not included with the to one of the auxiliary hydraulic couplers on the
CAS-1808 Flowmeter Fitting Kit or the CAS-1804 left hand loader arm.
Pressure Test Fitting Kit. The part numbers for the
auxiliary hydraulic couplers are 87417308 (male 4. Run the engine at full throttle. Actuate the
coupler) and 393394A1 (female coupler). auxiliary hydraulic flow control pedal to
pressurize the hydraulic line which has the
1. Park the machine on a level surface. Lower the pressure gauge. Record the indication on the
loader bucket to the floor. pressure gauge. Then return the auxiliary
2. The oil must be at operating temperature. To hydraulic flow control pedal to the Neutral
heat the oil, do the following steps: position and decrease the engine speed to low
idle. Stop the engine.
A. With the engine running at full throttle, hold
the bucket control lever in the ROLLBACK 5. Compare the indication with the specification on
position for 10 seconds. page 3. If the indication is not correct, see page 9
and 10 for the location of the main relief valve.
B. Put the bucket control lever in the NEUTRAL Adjust the main relief valve. Then do the
position for 10 seconds. pressure check again to make sure that the
C. Repeat steps A and B until the temperature of setting is correct.
the oil is 52° C (125° F) or the side of the
reservoir is very warm.

TESTING CIRCUIT RELIEF VALVES WITH A HAND PUMP

1. Park the machine on a level surface. 9. Operate the hand pump to fill the hose of the
hand pump with oil. Then tighten the
2. Lower all attachments to the floor.
connections.
3. Stop the engine.
10. Operate the hand pump and read the pressure
4. Move the control levers in all directions to gauge. Record the highest indication. Check the
release any circuit pressure. pressure several times to make sure that the
indications are correct.
5. The best way to connect the hand pump is
directly to the control valve. Disconnect the tube 11. Compare the indication with the specification on
from the port of the control valve and connect the page 3. If the indication is not correct, replace the
hand pump to the port. By connecting directly to circuit relief valve.
the control valve, you avoid the possibility of a
NOTE: The circuit relief valves for the loader circuit
bad reading because of cylinder movement.
are not adjustable and must be replaced if they do
6. Remove all dirt and grease from the connecting not meet the specification.
point.
12. Repeat this test after installing a new circuit relief
7. Connect the hose of the hand pump to the valve.
connecting point, but do not tighten the
connection.
8. Make sure that the hand pump is filled with oil.
The temperature of the oil must be at least 21° C
(70° F).

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8001-6

FLOWMETER TESTS
7. Make sure that the pressure valve is opened
WARNING: Two persons are required to completely. Adjust the engine speed to 2200
! perform the flowmeter tests for safety to r/min (rpm) and read the flow gauge. Write the
avoid possible injury. One person must be indication on line 1 on the check sheet.
seated in the operators seat with the Seat 8. Slowly close the pressure valve on the flowmeter
Bar down when the engine is running. The until the pressure gauge indicates 97 bar (1400
second person is to control the flowmeter psi). Keep the engine running at 2200 r/min
and take the readings. CSM118 (rpm). Read the flow gauge and write the
indication on line 2 on the check sheet.

General Information 9. Slowly close the pressure valve on the flowmeter

until the pressure gauge indicates 124 bar (1800
The flowmeter measures the volume, pressure, and psi). Keep the engine running at 2200 r/min
temperature of the hydraulic oil as the hydraulic oil (rpm). Read the flow gauge and write the
flows through the flowmeter. indication on line 3 on the check sheet.
Test No. 1 will indicate whether or not there are 10. Slowly close the pressure valve on the flowmeter
problems in the line between the reservoir and the until the pressure gauge indicates 152 bar (2000
gear pump and whether or not the gear pump is psi). Keep the engine running at 2200 r/min
working within acceptable standards of efficiency. (rpm). Read the flow gauge and write the
Test No. 2 will indicate whether or not there are indication on line 4 on the check sheet.
problems in the loader hydraulic circuits. 11. Open the pressure valve completely. Decrease
There is a check sheet at the end of this section. You the engine speed to low idle and stop the engine.
can make copies of the check sheet to record the test
results. Understanding the Results
NOTE: Use an accurate tachometer to adjust and 1. If the output at minimum pressure was less than
maintain engine speeds during these tests. the specification for Gear Pump Flow to Loader
(Machine in Neutral) shown on page 3, the
Test No. 1 - Gear Pump problem can be a restriction between the
reservoir and the gear pump, or the problem can
1. Park the machine on a level surface. Lower the be a badly worn or damaged gear pump.
loader bucket to the floor. Stop the engine.
2. If the output at minimum pressure was more than
2. Disconnect the hose from the fitting at Test Point the specification on page 3, there are no
1 (pressure port). Install a plug in the hose. problems between the reservoir and the gear
Connect the flowmeter inlet hose to the pressure pump. However, the gear pump can be worn or
port fitting. damaged and still have good flow at minimum
pressure.
3. Put the flowmeter outlet hose into the hydraulic
reservoir. Use wire to fasten the flowmeter outlet 3. Loss of output at 152 bar (2200 psi) indicates
hose below the surface of the hydraulic oil. that the gear pump is worn or damaged. To
determine the efficiency of the gear pump, divide
4. Make sure that the oil level in the hydraulic
the flow indication from line 4 by the flow
reservoir is correct.
indication from line 1. This answer multiplied by
5. Make sure that the pressure valve of the 100 is the percent efficiency of the gear pump. If
flowmeter is opened completely. the efficiency of the gear pump is less than 75%,
repair or replace the gear pump. If the efficiency
6. The oil must be at operating temperature. If the
of the gear pump is more than 75%, the pump is
oil is not at operating temperature, run the
good.
engine at full throttle and close the pressure
valve of the flowmeter until the pressure gauge NOTE: The flow at the other pressures will be used
indicates 103 bar (1500 psi). Continue to run the in the remaining tests.
engine at full throttle until the temperature of the
oil is 52° C (125° F). Then open the pressure
valve completely.

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 8001-7

Test No. 2 - Loader Circuits and 10. Start the engine and run the engine at 2200 r/min
(rpm).
Main Relief Valve
11. Hold the bucket control lever in the ROLLBACK
1. Park the machine on a level surface. Lower the position and close the pressure valve on the
loader bucket to the floor. Stop the engine. flowmeter until the pressure gauge indicates 124
2. Disconnect the flowmeter inlet hose from the bar (1800 psi). Adjust the engine speed to keep
elbow at Test Point 1. Remove the plug which the engine running at 2200 r/min (rpm). Read the
you installed in the hose to the loader control flow gauge and write the indication on line 7 on
valve (Test No. 1 - step 2) and reconnect the the check sheet.
hose to the Tee fitting. Connect the flowmeter 12. Hold the bucket control lever in the DUMP
inlet hose to the tee. Leave the flowmeter outlet position and adjust the pressure valve on the
hose in the hydraulic reservoir as in Test No. 1 - flowmeter until the pressure gauge indicates 124
Gear Pump. bar (1800 psi). Adjust the engine speed to keep
3. Make sure that the oil level in the hydraulic the engine running at 2200 r/min (rpm). Read the
reservoir is correct. flow gauge and write the indication on line 8 on
4. The oil must be at operating temperature. If the the check sheet.
oil is not at operating temperature, run the 13. Hold the lift control lever in the LIFT position and
engine at full throttle. Hold the auxiliary hydraulic adjust the pressure valve on the flowmeter until
flow control pedal in the ON position and close the pressure gauge indicates 124 bar (1800 psi).
the pressure valve of the flowmeter until the Adjust the engine speed to keep the engine
pressure gauge indicates 103 bar (1500 psi). running at 2200 r/min (rpm). Read the flow
Continue to run the engine at full throttle until the gauge and write the indication on line 9 on the
temperature of the oil is 52° C (125° F). check sheet.
5. Continue to hold the auxiliary hydraulic flow 14. Hold the lift control lever in the LOWER position
control pedal in the ON position. Continue to run and adjust the pressure valve on the flowmeter
the engine at full throttle. Slowly close the until the pressure gauge indicates 124 bar (1800
pressure valve. As the pressure increases, the psi). Adjust the engine speed to keep the engine
flow indication will decrease slowly. As you running at 2200 r/min (rpm). Read the flow
continue to close the pressure valve, you will gauge and write the indication on line 10 on the
reach a point at which the flow indication begins check sheet.
to decrease rapidly. This is the point at which the
main relief valve starts to open. Read the Auxiliary Circuits
pressure gauge and write the indication on line 5 NOTE: Both of the loader control valve spools must
on the check sheet. be in the NEUTRAL position during the following test.
6. Continue to close the pressure valve until the NOTE: If the auxiliary hydraulic circuit is connected
indication of the flow gauge is zero. This is the to an attachment using a hydraulic motor, this flow
point at which the main relief valve is completely test does not apply.
open. Read the pressure gauge and write the
indication on line 6 on the check sheet. 15. Push down one side of the auxiliary hydraulic
flow control pedal and adjust the pressure valve
7. Open the pressure valve completely. Decrease on the flowmeter until the pressure gauge
the engine speed to low idle and stop the engine. indicates 124 bar (1800 psi). Adjust the engine
8. If the pressure setting of the main relief valve is speed to keep the engine running at 2200 r/min
not as specified on page 3, try to adjust the main (rpm). Read the flow gauge and write the
relief valve. See page 9 and 10 for the location of indication on line 11 of the check sheet.
the main relief valve. If the main relief valve 16. Push down the opposite side of the auxiliary
cannot be adjusted to the correct setting, you hydraulic flow control pedal and adjust the
must replace the main relief valve. pressure valve on the flowmeter until the
9. If you adjusted, repaired, or replaced the main pressure gauge indicates 124 bar (1800 psi).
relief valve, repeat steps 5 through 7. Adjust the engine speed to keep the engine
If the completely open pressure (step 6) is as running at 2200 r/min (rpm). Read the flow
specified, but the pressure at which the main relief gauge and write the indication on line 12 of the
valve begins to open (step 5) is 183 bar (2400 psi) or check sheet.
less, the main relief valve is damaged and must be 17. Open the pressure valve completely. Decrease
replaced before you do further testing. the engine speed to low idle and stop the engine.

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8001-8
Understanding the Results 21. Leakage in the lift circuits can be caused by any
of the following problems:
18. If the flow indication for a circuit was
approximately the same as the flow indication at A. Damaged or worn packing in one or both of
the same pressure in Test No. 1, the circuit is the lift cylinders.
good. B. Damaged or worn spool or spool bore in the
19. If the flow indication for a circuit was more than loader control valve.
3.8 L/min (one gpm) less than the flow indication C. Defective circuit relief valves.
at the same pressure in Test No. 1, there is
D. Inadequate control spool travel.
leakage in that circuit.
22. Leakage in the auxiliary circuits can be caused
20. Leakage in the bucket circuits can be caused by
by any of the following problems:
any of the following problems:
A. Inadequate control spool travel.
A. Damaged or worn packing in one or both of
the bucket cylinders. B. Damaged or worn packing in one or both of
the cylinders.
B. Damaged or worn spool or spool bore in the
loader control valve. C. Damaged or worn spool or spool bore in the
loader control valve.
C. Self-leveling valve (if equipped) is sticking or
has worn spools. 23. If the flow indication for every circuit tested was
more than 3.8 L/min (one gpm) less than the flow
D. Defective circuit relief valves.
indication at the same pressure in Test No. 1,
E. Inadequate control spool travel. there is leakage at a point common to the entire
system. A probable cause is a damaged or worn
main relief valve or seals.

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 8001-9

11

10

7 8

5 9

6
6
4

2 6 3
1

BS05A075
1. LIFT SPOOL 7. TILT CYLINDERS
2. TILT SPOOL 8. LIFT CYLINDERS
3. AUXILIARY SPOOL 9. AUXILIARY OUTLETS
4. MAIN RELIEF VALVE 10. OIL COOLER
5. CIRCUIT RELIEF VALVE 11. OIL COOLER BYPASS VALVE
6. CHECK VALVE
3 SPOOL LOADER CONTROL VALVE SCHEMATIC

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8001-10

5
8 9

10

4
7
6

6
3
1 2

11

BS05A082
1. LIFT SPOOL 7. AUXILIARY SPOOL SWITCH
2. TILT SPOOL 8. SHUTOFF PLUG
3. AUXILIARY SPOOL 9. ANTI CAVITATION VALVE (IF EQUIPPED)
4. MAIN RELIEF VALVE 10. SPRING
5. CIRCUIT RELIEF VALVE 11. POPPET
6. SPOOL LOCKOUT SOLENOID
LOADER CONTROL VALVE

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 8001-11

METRIC MEASURE CHECK SHEET

Owner ________________________________________________ Date __________ Hours________________
Model _________________________________________ Product Identification Number __________________
Oil Temperature: At start of test ______ ° C. At end of test ______ ° C.

Test No. 1 - Gear Pump

1. _________ L/min at min. pressure at 2200 r/min 3. _________ L/min at 124 bar at 2200 r/min
2. _________ L/min at 97 bar at 2200 r/min 4. _________ L/min at 152 bar at 2200 r/min
The efficiency of the gear pump is line 4 divided by line 1.

Test No. 2 - Loader Circuits and Main Relief Valve

5. Main relief valve begins to open at ________ bar 9. Lift ______________________ L/min at 124 bar
6. Main relief valve completely open at _______ bar 10. Lower ____________________ L/min at 124 bar
7. Rollback __________________ L/min at 124 bar 11. Auxiliary __________________ L/min at 124 bar
8. Dump ____________________ L/min at 124 bar 12. Auxiliary __________________ L/min at 124 bar

U.S. MEASURE CHECK SHEET

Owner ________________________________________________ Date __________ Hours________________
Model _________________________________________ Product Identification Number __________________
Oil Temperature: At start of test ______ ° F. At end of test ______ ° F.

Test No. 1 - Gear Pump

1. _________ gpm at min. pressure at 2000 rpm 3. _________ gpm at 1800 psi at 2000 rpm
2. _________ gpm at 1400 psi at 2000 rpm 4. _________ gpm at 2200 psi at 2000 rpm
The efficiency of the gear pump is line 4 divided by line 1.

Test No. 2 - Loader Circuits and Main Relief Valve

5. Main relief valve begins to open at ________ psi 12. Auxiliary __________________ gpm at 1800 psi
6. Main relief valve completely open at _______ psi
7. Rollback __________________ gpm at 1800 psi
8. Dump ____________________ gpm at 1800 psi
9. Lift _______________________ gpm at 1800 psi
10. Lower ____________________ gpm at 1800 psi
11. Auxiliary __________________ gpm at 1800 psi
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8001-12

1. LEFT PISTON PUMP 12. RIGHT BRAKE

2. RIGHT PISTON PUMP 13. FLUSHING VALVE
3. CHARGE PUMP 14. BRAKE SOLENOID VALVE
4. HYDROSTATIC PUMP 15. CHARGE PRESSURE SWITCH
5. CIRCUIT RELIEF VALVE 16. ORIFICE
6. TOW VALVE 17. HYDRAULIC RESERVOIR
7. CHECK VALVE 18. DRAIN MANIFOLD
8. HYDRAULIC GEAR PUMP 21. BACKUP ALARM SWITCH PORTS
9. LEFT DRIVE MOTOR 22. BRAKE LIGHT SWITCH PORTS
10. RIGHT DRIVE MOTOR 25. MAIN RELIEF VALVE
11. LEFT BRAKE 44. 100 MESH SCREEN
410 HYDRAULIC SCHEMATIC FRAME 1

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 8001-13

5. RELIEF VALVE 26. LOADER CONTROL VALVE

16. ORIFICE 27. TILT SPOOL
19. OIL COOLER 28. LIFT SPOOL
20. OIL COOLER BYPASS VALVE 29. AUXILIARY SPOOL
23. TILT CYLINDER 30. AUXILIARY OUTLETS
24. LIFT CYLINDER
410 HYDRAULIC SCHEMATIC FRAME 2

Bur 6-79511 Revised 3-06 Printed in U.S.A.

8001-14

5. CIRCUIT RELIEF VALVE 30. AUXILIARY OUTLETS

16. ORIFICE 37. NOT USED
26. LOADER CONTROL VALVE 38. NOT USED
27. TILT SPOOL 39. NOT USED
28. LIFT SPOOL 40. ATTACHMENT CASE DRAIN
29. AUXILIARY SPOOL 45. ACCUMULATOR
410 HYDRAULIC SCHEMATIC FRAME 3

Bur 6-79511 Revised 3-06 Printed in U.S.A.

 8001-15

40. ATTACHMENT CASE DRAIN 42. HYDRAULIC COUPLER CYLINDER

41. HYDRAULIC COUPLER CONTROL VALVE 46. CHECK VALVE
410 HYDRAULIC SCHEMATIC FRAME 4

Bur 6-79511 Revised 3-06 Printed in U.S.A.

8001-16

43. SECONDARY AUXILIARY CONTROL VALVE

410 HYDRAULIC SCHEMATIC FRAME 5

Bur 6-79511 Revised 3-06 Printed in U.S.A.

 8001-17

47. SELF LEVEL VALVE

410 HYDRAULIC SCHEMATIC FRAME 6

Bur 6-79511 Revised 3-06 Printed in U.S.A.

8001-18

45. ACCUMULATOR 48. RIDE CONTROL SOLENOID VALVE

410 HYDRAULIC SCHEMATIC FRAME 7

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 8001-19
NOTES

Bur 6-79511 Revised 3-06 Printed in U.S.A.

8001-20

1. LEFT PISTON PUMP 12. RIGHT BRAKE

2. RIGHT PISTON PUMP 13. FLUSHING VALVE
3. CHARGE PUMP 14. BRAKE SOLENOID VALVE
4. HYDROSTATIC PUMP 15. CHARGE PRESSURE SWITCH
5. CIRCUIT RELIEF VALVE 16. ORIFICE
6. TOW VALVE 17. HYDRAULIC RESERVOIR
7. CHECK VALVE 18. DRAIN MANIFOLD
8. HYDRAULIC GEAR PUMP 21. BACKUP ALARM SWITCH PORTS
9. LEFT DRIVE MOTOR 22. BRAKE LIGHT SWITCH PORTS
10. RIGHT DRIVE MOTOR 25. MAIN RELIEF VALVE
11. LEFT BRAKE 44. 100 MESH SCREEN
420 HYDRAULIC SCHEMATIC FRAME 1

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 8001-21

5. RELIEF VALVE 26. LOADER CONTROL VALVE

16. ORIFICE 27. TILT SPOOL
19. OIL COOLER 28. LIFT SPOOL
20. OIL COOLER BYPASS VALVE 29. AUXILIARY SPOOL
23. TILT CYLINDER 30. AUXILIARY OUTLETS
24. LIFT CYLINDER
420 HYDRAULIC SCHEMATIC FRAME 2

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8001-22

5. CIRCUIT RELIEF VALVE 30. AUXILIARY OUTLETS

16. ORIFICE 37. HIGH FLOW PUMP
26. LOADER CONTROL VALVE 38. HIGH FLOW OIL COOLER
27. TILT SPOOL 39. HIGH FLOW CONTROL VALVE
28. LIFT SPOOL 40. ATTACHMENT CASE DRAIN
29. AUXILIARY SPOOL 45. ACCUMULATOR
420 HYDRAULIC SCHEMATIC FRAME 3

Bur 6-79511 Revised 3-06 Printed in U.S.A.

 8001-23

40. ATTACHMENT CASE DRAIN 42. HYDRAULIC COUPLER CYLINDER

41. HYDRAULIC COUPLER CONTROL VALVE 46. CHECK VALVE
420 HYDRAULIC SCHEMATIC FRAME 4

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8001-24

43. SECONDARY AUXILIARY CONTROL VALVE

420 HYDRAULIC SCHEMATIC FRAME 5

Bur 6-79511 Revised 3-06 Printed in U.S.A.

 8001-25

47. SELF LEVEL VALVE

420 HYDRAULIC SCHEMATIC FRAME 6

Bur 6-79511 Revised 3-06 Printed in U.S.A.

8001-26

45. ACCUMULATOR 48. RIDE CONTROL SOLENOID VALVE

420 HYDRAULIC SCHEMATIC FRAME 7

Bur 6-79511 Revised 3-06 Printed in U.S.A.

 Section
8003

8003
REMOVAL AND INSTALLATION OF HYDRAULIC
COMPONENTS

CNH AMERICA LLC Copyright © 2005 CNH America LLC

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79520 February, 2005
8003-2

TABLE OF CONTENTS
GEAR (EQUIPMENT) PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC FILTER BASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HIGH FLOW PUMP (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HIGH FLOW VALVE (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HIGH FLOW ACCUMULATOR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECONDARY FRONT AUXILIARY HYDRAULICS CONTROL VALVE
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RIDE CONTROL ACCUMULATOR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RIDE CONTROL SOLENOID VALVE (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SOLENOID VALVE FOR HYDRAULIC COUPLER
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CHECK VALVE FOR HYDRAULIC COUPLER
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
HYDRAULIC OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
HIGH FLOW OIL COOLER (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SELF LEVELING VALVE (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Bur 6-79520 Issued 2-05 Printed in U.S.A.

 8003-3

GEAR (EQUIPMENT) PUMP

Removal Installation
1. Loosen and remove the bolts from the cover on 13. Hold the gear pump (2) against the tandem
the kick plate (1). pump mounting location, refer to the photo
below. Rotate the gear pump shaft until it aligns
2. Place a shop towel under the gear pump (2).
with the coupling splines.
3. Remove the cap from the hydraulic reservoir.
14. Apply Loctite 243 to the flange bolts (3). Install
4. Connect a vacuum pump to the hydraulic washers (4) and flange bolts (3), and tighten
reservoir. flange bolts (3).
5. Start the vacuum pump. 15. Start the vacuum pump.
6. Tag and disconnect the hose from the fitting at 16. Connect the hoses to the suction port (5) and
the suction port (5) of the gear pump (2). pressure port(s) side (6) of the gear pump (2).
7. Install a plug in the hose and a cap on the fitting. 17. Stop the vacuum pump. Disconnect the vacuum
pump from the hydraulic reservoir. Install the cap
8. Tag and disconnect the hose from the pressure
on the hydraulic reservoir.
port(s) (6) of the gear pump (2).
18. Clean up any hydraulic fluid from equipment or
9. Install a plug in the hose(s) and a cap on the
floor.
fitting(s).
19. Start and run the engine at low idle.
10. Stop the vacuum pump.
20. Stop the engine.
11. Remove the flange bolts (3) and washers (4),
refer to the photo below. 21. Check for oil leakage.
12. Remove the gear pump (2) from the tandem 22. Check the level of the oil in the hydraulic
pump mounting location. reservoir. Add oil as required.
23. Install the cap on the hydraulic reservoir.
24. Install the cover plate on the plate (1) and tighten
the mounting bolts.

1 3 4

3 4
6

5
6

2
BD05A085
GEAR PUMP MOUNTING

Bur 6-79520 Issued 2-05 Printed in U.S.A.

8003-4

LOADER CONTROL VALVE

Removal Installation
1. Install the loader control valve (1) in the chassis
mounting location.
2. Install the mounting bolts which fasten the loader
control valve (1) to the chassis. Tighten the
1 mounting bolts.
3. Install the hydraulic override cable to the loader
control valve (1).
4. Install all of the control linkage to the loader
control valve (1).
5. Connect the electrical connectors to the loader
BD05B009 control valve (1).
1. Remove the cap from the hydraulic reservoir. 6. Start the vacuum pump.
2. Connect a vacuum pump to the hydraulic 7. Remove the plugs from the fittings and caps from
reservoir. the connections.
3. Start the vacuum pump. 8. Install all of the hydraulic lines and hoses to the
4. Tag and disconnect all of the hydraulic lines and correct connections on the loader control valve
hoses that are connected to the loader control (1). Tighten all of the hydraulic connections.
valve (1). 9. Stop the vacuum pump.
5. Install plugs in the fittings and caps on the 10. Remove the vacuum pump from the hydraulic
connections. reservoir. Install the cap on the reservoir.
6. Stop the vacuum pump. 11. Clean up any hydraulic fluid from equipment or
7. Tag and disconnect the electrical connectors floor.
from the loader control valve (1). 12. Start and run the engine at low idle.
8. Disconnect all of the control linkage from the 13. Operate the loader controls to completely extend
loader control valve (1). and retract the lift and tilt cylinders in order to
remove any air from the hydraulic system.
9. Disconnect the hydraulic override cable from the
loader control valve (1). 14. Lower the loader arm to the floor.
15. Stop the engine.
10. Loosen and remove the mounting bolts which
fasten the loader control valve (1) to the chassis. 16. Check for oil leakage.

11. Remove the loader control valve (1) from the 17. Check the level of the oil in the hydraulic
chassis mounting location. reservoir. Add oil as required.

Bur 6-79520 Issued 2-05 Printed in U.S.A.

 8003-5

1 6
5

3 2

BS05B066
1. LOADER CONTROL VALVE 4. LIFT SPOOL
2. LIFT CYLINDER 5. TILT SPOOL
3. TILT CYLINDER 6. AUXILIARY SPOOL
LOADER CONTROL VALVE HYDRAULIC INSTALLATION

Bur 6-79520 Issued 2-05 Printed in U.S.A.

8003-6

HYDRAULIC FILTER BASE ASSEMBLY

Removal Installation
1. Place a shop towel under the hydraulic filter. 1. Install the hydraulic filter, washers, and bolts to
the bracket.
2. Remove the cap from the hydraulic reservoir.
2. Install the electrical connection to the hydraulic
3. Connect a vacuum pump to the hydraulic
filter indicator switch assembly.
reservoir.
3. Start the vacuum pump.
4. Start the vacuum pump.
4. Connect all hoses to the hydraulic filter.
5. Tag and disconnect all hoses from the hydraulic
filter. 5. Stop the vacuum pump. Disconnect the vacuum
pump from the hydraulic reservoir. Install the cap
6. Install plugs in the hoses and caps on the fittings.
on the hydraulic reservoir.
7. Tag and disconnect electrical connection from
6. Clean up any hydraulic fluid from equipment or
the hydraulic filter indicator switch assembly.
floor.
8. Remove the bolts, washers, and hydraulic filter
7. Start and run the engine at low idle.
from the bracket.
8. Operate the loader controls to completely extend
9. Stop the vacuum pump.
and retract the lift and tilt cylinders to remove any
air from the hydraulic system.
Inspection
9. Lower the loader bucket to the floor.
1. Inspect the hydraulic filter head and indicator
switch assembly for damage. Replace all 10. Stop the engine.
damaged parts. 11. Check for oil leakage.
2. Inspect the hydraulic filter mounting bracket for 12. Check the level of the oil in the hydraulic
corrosion or damage. Replace all damaged reservoir. Add oil as required.
parts.
13. Install the cap on the hydraulic reservoir.

Bur 6-79520 Issued 2-05 Printed in U.S.A.

 8003-7

BS04M122
1. BRACKET 8. NUT
2. BOLT 9. LOCK WASHER
3. LOCK NUT 10. O-RING
4. BOLT 11. O-RING
5. WASHER 12. INDICATOR
6. FILTER HEAD 13. FILTER ELEMENT
7. WASHER
HYDRAULIC FILTER BASE ASSEMBLY

Bur 6-79520 Issued 2-05 Printed in U.S.A.

8003-8

HIGH FLOW PUMP (IF EQUIPPED)

Removal Installation
1. Loosen and remove the bolts from the cover on 13. Hold the High Flow pump (2) against the tandem
the kick plate (1). pump mounting location, refer to the photo
below. Rotate the High Flow pump shaft until it
2. Place a shop towel under the High Flow pump
aligns with the coupling splines.
(2).
14. Apply Loctite 243 to the flange bolts (3). Install
3. Remove the cap from the hydraulic reservoir.
washers (4) and flange bolts (3), and tighten
4. Connect a vacuum pump to the hydraulic flange bolts (3).
reservoir.
15. Start the vacuum pump.
5. Start the vacuum pump.
16. Connect the hoses to the suction port (5) and
6. Tag and disconnect the hose from the fitting at pressure port(s) side (6) of the High Flow pump
the suction port (5) of the High Flow pump (2). (2).
7. Install a plug in the hose and a cap on the fitting. 17. Stop the vacuum pump. Disconnect the vacuum
pump from the hydraulic reservoir. Install the cap
8. Tag and disconnect the hose from the pressure
on the hydraulic reservoir.
port(s) (6) of the High Flow pump (2).
18. Clean up any hydraulic fluid from equipment or
9. Install a plug in the hose(s) and a cap on the
floor.
fitting(s).
19. Start and run the engine at low idle.
10. Stop the vacuum pump.
20. Stop the engine.
11. Remove the flange bolts (3) and washers (4),
refer to the photo below. 21. Check for oil leakage.
12. Remove the High Flow pump (2) from the 22. Check the level of the oil in the hydraulic
tandem pump mounting location. reservoir. Add oil as required.
23. Install the cap on the hydraulic reservoir.
24. Install the cover plate on the plate (1) and tighten
the mounting bolts.

1 3 4

3 4
6

5
6

2
BD05A085
HIGH FLOW PUMP

Bur 6-79520 Issued 2-05 Printed in U.S.A.

 8003-9

HIGH FLOW VALVE (IF EQUIPPED)

Removal Installation
1. Install the high flow valve (1) into the chassis
mounting location.
2. Install and tighten the high flow valve mounting
bolts.
3. Reconnect the electrical harness to the high flow
valve (1) solenoid valve.
1
4. Start the vacuum pump.
5. Remove the plugs in the fittings and a caps from
the connections.
6. Connect all of the hydraulic connections on high
BD05B009
1. HIGH FLOW VALVE flow valve (1). Tighten all of the hydraulic
connections.
1. Place a shop towel under the high flow valve (1).
7. Stop the vacuum pump.
2. Remove the cap from the hydraulic reservoir.
8. Disconnect the vacuum pump from the hydraulic
3. Connect a vacuum pump to the hydraulic reservoir. Install the cap on the hydraulic
reservoir. reservoir.
4. Start the vacuum pump. 9. Clean up any hydraulic fluid from equipment or
5. Tag and disconnect all of the hydraulic floor.
connections on high flow valve (1). 10. Start and run the engine at low idle.
6. Install a plugs in the fittings and a caps on the 11. Engage the high flow hydraulics.
connections.
12. Stop the engine.
7. Stop the vacuum pump.
13. Check for oil leakage.
8. Disconnect the electrical harness from the high
flow valve (1) solenoid valve. 14. Check the level of the oil in the hydraulic
reservoir. Add oil as required.
9. Loosen and remove the high flow valve mounting
bolts. 15. Install the cap on the hydraulic reservoir.

10. Remove the high flow valve (1) from the chassis
mounting location.

Bur 6-79520 Issued 2-05 Printed in U.S.A.

8003-10

HIGH FLOW ACCUMULATOR (IF EQUIPPED)

Removal Installation
1. Install the high flow accumulator (1) in the
WARNING: DO NOT attempt to chassis mounting location.
disassemble any accumulator until the
nitrogen charge is properly discharged. 2. Install the mounting bolts which fasten the high
SM386\ flow accumulator (1) to the chassis. Tighten the
SM386\
mounting bolts.
IMPORTANT: Follow the procedure for Discharging
an Accumulator in Section 8013 before attempting to 3. Start the vacuum pump.
remove the accumulator from the machine. 4. Remove the plug in the fitting and a cap on the
connection.

1 5. Install the hydraulic connection to high flow

accumulator (1). Tighten the connection.
6. Stop the vacuum pump.
7. Disconnect the vacuum pump from the hydraulic
reservoir. Install the cap on the hydraulic
reservoir.
8. Follow the procedure in Section 8013 for
Charging the Accumulator With Dry Nitrogen.
9. Start and run the engine at low idle.
BD05B010
1. HIGH FLOW ACCUMULATOR
10. Engage the high flow hydraulics.
1. Place a shop towel under the high flow
11. Stop the engine.
accumulator (1).
12. Check for oil leakage.
2. Remove the cap from the hydraulic reservoir.
13. Check the level of the oil in the hydraulic
3. Connect a vacuum pump to the hydraulic
reservoir. Add oil as required.
reservoir.
14. Install the cap on the hydraulic reservoir.
4. Start the vacuum pump.
5. Tag and disconnect the hydraulic connection to
high flow accumulator (1).
6. Install a plug in the fitting and a cap on the
connection.
7. Stop the vacuum pump.
8. Loosen and remove the mounting bolts which
fasten the high flow accumulator (1) to the
chassis.
9. Remove the high flow accumulator (1) from the
chassis mounting location.

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 8003-11

2
3

BS05C073
1. LOADER CONTROL VALVE 3. HIGH FLOW ACCUMULATOR
2. HIGH FLOW VALVE 4. RETURN OIL MANIFOLD

HIGH FLOW COMPONENTS (IF EQUIPPED)

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8003-12

SECONDARY FRONT AUXILIARY HYDRAULICS CONTROL VALVE

(IF EQUIPPED)

Removal Installation
1. Remove the floorplate from the machine. 1. Install the control valve (1) into the chassis
2. Place a shop towel under the control valve (1). mounting location.

3. Remove the cap from the hydraulic reservoir. 2. Install and tighten the control valve mounting
bolts (3).
4. Connect a vacuum pump to the hydraulic
reservoir. 3. Start the vacuum pump.

5. Start the vacuum pump. 4. Remove the plugs in the fittings and a caps from
the connections.
5. Connect all of the hydraulic connections on
2 control valve (1). Tighten all of the hydraulic
connections.
3 6. Stop the vacuum pump.
1
7. Disconnect the vacuum pump from the hydraulic
reservoir. Install the cap on the hydraulic
3
reservoir.
8. Clean up any hydraulic fluid from equipment or
floor.
BS05C081 9. Start and run the engine at low idle.
6. Tag and disconnect all of the hydraulic
10. Engage the secondary front auxiliary hydraulics.
connections on control valve (1).
11. Stop the engine.
7. Install a plugs in the fittings and a caps on the
connections. 12. Check for oil leakage.
8. Stop the vacuum pump. 13. Check the level of the oil in the hydraulic
reservoir. Add oil as required.
9. Remove the clip from the pin and remove the pin
from the clevis (2). 14. Install the cap on the hydraulic reservoir.
10. Loosen and remove the control valve mounting
bolts (3).
11. Remove the control valve (1) from the chassis
mounting location.

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3
2

BS05C082
1. CONTROL VALVE 3. COUPLERS
2. PEDAL
SECONDARY FRONT AUXILIARY HYDRAULICS (IF EQUIPPED)

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8003-14

RIDE CONTROL ACCUMULATOR (IF EQUIPPED)

Removal Installation
WARNING: DO NOT attempt to STEP 1
disassemble any accumulator until the
nitrogen charge is properly discharged.
SM386\

IMPORTANT: Follow the procedure for Discharging

an Accumulator in Section 8013 before attempting to
remove the accumulator from the machine.
2
STEP 1
Remove the cap from the hydraulic reservoir. 1
Connect a vacuum pump to the hydraulic reservoir.
Start the vacuum pump.
BD05B012
STEP 2 Install the accumulator into the chassis mounting
location. Secure the clamps (1) around the
accumulator (2) and tighten the clamps (1).

1 STEP 2
Start the vacuum pump.

STEP 3

2 1
BD05B012

Loosen and remove the hydraulic hose connection

(1) from the accumulator (2). Install a plug in the
hose and a cap on the fitting. Stop the vacuum pump.

STEP 3
2
BD05B012

Remove the plug from the hose and the cap from the
fitting. Install the hydraulic hose connection (1) to the
accumulator (2). Tighten the hydraulic connection
2 (1). Stop the vacuum pump and remove the vacuum
pump from the hydraulic reservoir. Install the cap on
the hydraulic reservoir.
1
STEP 4
Follow the procedure in Section 8013 for Charging
BD05B012 the Accumulator With Dry Nitrogen.
Loosen and remove the 2 clamps (1) which mount
the accumulator (2) to the chassis. Remove the STEP 5
accumulator (2) from the chassis. Start the engine and run at low idle. Check for leaks.
Stop the engine and check the hydraulic oil level in
the reservoir. Add hydraulic oil as required. Install the
cap on the reservoir.

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 8003-15

RIDE CONTROL SOLENOID VALVE (IF EQUIPPED)

Removal STEP 4

STEP 1
Remove the cap from the hydraulic reservoir.
Connect a vacuum pump to the hydraulic reservoir.
Start the vacuum pump.

STEP 2

1 BD05B011

Loosen and remove the mounting bolts from the

solenoid valve. Remove the valve from the machine.

BD05B011

Tag and loosen and remove the hydraulic

connections from the solenoid valve (1). Place a cap
on the fittings and plugs in the hoses. Stop the
vacuum pump.

STEP 3

BD05B011

Disconnect the electrical harness to the solenoid

valve.

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8003-16

Installation STEP 3

STEP 1

BD05B011

Start the vacuum pump. Remove the caps from the

BD05B011
fitting and the plugs from the hoses. Connect the
Install the solenoid valve (1) into the mounting hydraulic hoses to the solenoid valve (1) and tighten
location. Install the mounting bolts into the solenoid the connections. Stop the vacuum pump and remove
valve (1) and tighten the mounting bolts. the vacuum pump from the hydraulic reservoir. Install
the cap on the hydraulic reservoir.
STEP 2
STEP 4
Start the engine and run at low idle. Check for leaks.
Stop the engine and check the hydraulic oil level in
the reservoir. Add hydraulic oil as required. Install the
cap on the reservoir.

BD05B011

Connect the electrical harness to the solenoid valve.

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4
1

BS05B088
1. ACCUMULATOR 3. LOADER CONTROL VALVE
2. SOLENOID VALVE 4. MANIFOLD VALVE
RIDE CONTROL HYDRAULIC INSTALLATION

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8003-18

SOLENOID VALVE FOR HYDRAULIC COUPLER

(IF EQUIPPED)

Removal STEP 4

STEP 1
Remove the cap from the hydraulic reservoir.
Connect a vacuum pump to the hydraulic reservoir.
Start the vacuum pump. 1
2
STEP 2

1 BD05B013

Loosen and remove the mounting bolts (2) from the

solenoid valve (1). Remove the solenoid valve (1)
from the machine.

BD05B013

Disconnect the electrical harness to the solenoid

valve (1).

STEP 3

BD05B013

Tag and disconnect all of the hydraulic hoses

connected to the solenoid valve (1). Install caps on
the fittings and plugs in the hoses. Stop the vacuum
pump.

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 8003-19

Installation STEP 3

STEP 1

1
2

BD05B013

Connect the electrical harness to the solenoid valve

BD05B013
(1) electrical connection.
Install the solenoid valve into the mounting location.
Install the mounting bolts (2) into the solenoid valve STEP 4
(1) and tighten the mounting bolts (2). Start the engine and run at low idle. Check for leaks.
Stop the engine and check the hydraulic oil level in
STEP 2 the reservoir. Add hydraulic oil as required. Install the
cap on the reservoir.

BD05B013

Start the vacuum pump. Remove the caps from the

fittings and the plugs from the hoses. Install the
hydraulic hoses to the correct fitting locations.
Tighten all of the hydraulic connections. Stop the
vacuum pump and remove the vacuum pump from
the hydraulic reservoir. Install the cap on the
hydraulic reservoir.

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8003-20

CHECK VALVE FOR HYDRAULIC COUPLER

(IF EQUIPPED)

Removal Installation
STEP 1
Remove the cap from the hydraulic reservoir.
Connect a vacuum pump to the hydraulic reservoir.
Start the vacuum pump.
2 1
STEP 2

1
BD05B014

Install the check valve (1) into the mounting location.

Install and tighten the mounting bolts (2).

STEP 4

BD05B014

Tag and disconnect all of the hydraulic hoses

connected to the check valve (1). Install caps on the
fittings and plugs in the hoses. Stop the vacuum 1
pump.

STEP 3

BD05B014

2 1
Start the vacuum pump. Remove the caps from the
fittings and plugs from the hoses. Install and tighten
all of the hydraulic hoses connected to the check
valve (1).

STEP 5
Stop the vacuum pump. Remove the vacuum pump
BD05B014 from the hydraulic reservoir. Install the cap on the
Loosen and remove the mounting bolts (2) from the hydraulic reservoir.
check valve (1). Remove the check valve (1) from the
machine. STEP 6
Start the engine and run at low idle. Check for leaks.
Stop the engine and check the hydraulic oil level in
the reservoir. Add hydraulic oil as required. Install the
cap on the reservoir.

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 8003-21

HYDRAULIC OIL COOLER

Removal STEP 6
NOTE: Photos may be slightly different from the
machine you are repairing. The procedure is the
same.
NOTE: Put caps on all fittings and plugs in all
disconnected hoses.

STEP 1 1
Park the machine on a level surface.

STEP 2
Lift the hood and open the rear access door on the BD05A024
machine. If equipped with a heater, open the heater coolant
valve (1).
STEP 3
Turn the ignition switch and the master disconnect STEP 7
switch (if equipped) to the OFF position.
Install a hose on the drain valve and drain the
radiator into a clean container that holds
STEP 4 approximately 17 litres (4.5 gallons).
Disconnect the negative battery cable from the
battery. STEP 8
If equipped with a heater, close the heater coolant
STEP 5 valve.

1 2 STEP 9
3
1

BD04C007

Slowly loosen the radiator cap (1). Disconnect the

overflow hose (2) from the radiator neck.
BD05A026

If the machine is equipped with a High Flow Oil

Cooler (1), release the latch (2) on the lower left side
of the oil cooler and swing the oil cooler away from
the radiator. Remove mounting bolts (3) from the
hinge and remove the oil cooler (1) from the radiator
mounting location. Secure the oil cooler away from
the radiator.

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8003-22
STEP 10 STEP 12

BD04C026 BD04K036

Release the latch on the top of the radiator and tip Move the radiator away from the upper radiator hose
the radiator out from the mounting location. and lower radiator hose. Remove the radiator from
the machine.
STEP 11
STEP 13
1 Remove the cap from the hydraulic reservoir.
Connect a vacuum pump to the hydraulic reservoir.
Start the vacuum pump.

STEP 14

1
3
BD04C007

2
BD04K036

Loosen and remove the upper (1) and lower (2)

1 hydraulic lines from the oil cooler (3). Place plugs in
the lines and caps on the fittings. Stop the vacuum
pump.

BD05A025

Loosen the clamps (1) on the lower radiator hose

and clamps (1) on the upper radiator hose. Remove
the upper radiator hose and the lower radiator hose
from the radiator.

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 8003-23
STEP 15 Installation
1
STEP 1
Installation of the oil cooler is the reverse procedure
1 of Removal.

STEP 2
After the oil cooler and radiator have been installed
1 fill the cooling system. See Section 1001 for the
correct coolant mixture and quantity.

2 STEP 3
BD04K036
Start the engine and run at low idle. Check for leaks.
Loosen and remove the mounting bolts which fasten Stop the engine and check the hydraulic oil level in
the oil cooler to the chassis. the reservoir. Add hydraulic oil as required. Install the
cap on the reservoir.
STEP 16
Remove the oil cooler from the chassis mounting STEP 4
location. After the engine has cooled, check the level of the
cooling system and add coolant as required.

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8003-24

HIGH FLOW OIL COOLER (IF EQUIPPED)

Removal STEP 7
NOTE: Photos may be slightly different from the 3
machine you are repairing. The procedure is the 1
same.
NOTE: Put caps on all fittings and plugs in all
disconnected hoses.
2
STEP 1
Park the machine on a level surface.

STEP 2
Lift the hood and open the rear access door on the BD05A026
machine. Release the latch (2) on the lower left side of the high
flow oil cooler (1) and swing the high flow oil cooler
STEP 3 (1) away from the radiator. Remove mounting bolts
Turn the ignition switch and the master disconnect (3) from the hinge and remove the high flow oil cooler
switch (if equipped) to the OFF position. (1) from the radiator mounting location.

STEP 4 Installation
Disconnect the negative battery cable from the
battery. STEP 1
Installation of the high flow oil cooler is the reverse
STEP 5 procedure of removal.
Remove the cap from the hydraulic reservoir.
Connect a vacuum pump to the hydraulic reservoir. STEP 2
Start the vacuum pump. After the high flow oil cooler has been installed, start
the engine and run at low idle. Check for leaks. Stop
STEP 6 the engine and check the hydraulic oil level in the
reservoir. Add hydraulic oil as required. Install the
cap on the reservoir
1

BD05A025

Loosen and remove the upper (1) and lower (2)

hydraulic lines from the oil cooler (3). Place plugs in
the lines and caps on the fittings. Stop the vacuum
pump.

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 8003-25

SELF LEVELING VALVE (IF EQUIPPED)

Removal Installation
1. Place a shop towel under the self leveling valve 1. Install the self leveling valve (1) into the chassis
(1). mounting location.
2. Remove the cap from the hydraulic reservoir. 2. Install and tighten the self leveling valve
mounting bolts.
3. Connect a vacuum pump to the hydraulic
reservoir. 3. Start the vacuum pump.
4. Start the vacuum pump. 4. Remove the plugs from the fittings and caps from
the connections.
5. Tag and disconnect all of the hydraulic
connections on self leveling valve (1). 5. Install all of the hydraulic connections to self
leveling valve (1). Tighten all the hydraulic
6. Install a plugs in the fittings and a caps on the
connections.
connections.
6. Stop the vacuum pump.
7. Stop the vacuum pump.
7. Remove the vacuum pump from the hydraulic
8. Loosen and remove the self leveling valve
reservoir. Install the cap on the hydraulic
mounting bolts.
reservoir.
9. Remove the self leveling valve (1) from the
8. Start the engine and run at low idle. Check for
chassis mounting location.
leaks. Stop the engine and check the hydraulic
oil level in the reservoir. Add hydraulic oil as
required. Install the cap on the reservoir.

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8003-26

2
1

BS05B101
1. SELF LEVELING VALVE 3. LOADER CONTROL VALVE
2. RELIEF VALVE
SELF LEVELING VALVE INSTALLATION

Bur 6-79520 Issued 2-05 Printed in U.S.A.

 SECTION INDEX

MOUNTED EQUIPMENT

Section Title Section Number

Pedals and Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9002
Attachment Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003
ROPS Canopy, Seat, Seat Belts, and Operators Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9004
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006

Copyright © 2005 CNH America LLC

All rights reserved.
CNH AMERICA LLC
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79110 Issued February, 2005
 9001
Section
9001

PEDALS AND LEVERS

CNH AMERICA LLC Copyright © 2005 CNH America LLC

700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 6-79500 February, 2005
9001-2

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THROTTLE CONTROL lever ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hand Throttle Lever Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hand Throttle Adjustment (With Foot Throttle Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONTROLS ADJUSTMENT PROCEDURE - LOADER FUNCTIONS AND NEUTRAL POSITION . . . . . . . . . . . 7
Control Handle Fore and Aft Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Controls - Pump Shim Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Controls Adjustment - Dynamic Straight Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SEAT BAR HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
AUXILIARY HYDRAULIC PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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 9001-3

SPECIFICATIONS
Engine Speeds 410 and 420 Machines)
Low Idle ............................................................................................................................... 1050 ± 50 r/min (rpm)
High Idle-- No Load .............................................................................................................. 3050 ± 50 r/min (rpm)
Rated --Full Load .......................................................................................................................... 2900 r/min (rpm

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9001-4

17

5
6

7
16 14

15

15
7
1

1
8

11
2
3
4
10
12 9

BS05B255

1. THROTTLE CONTROL LEVER 6. INJECTOR PUMP LEVER 11. THROTTLE PIVOT 16. FLYWHEEL COVER
2. NUT 7. BALL JOINT 12. THROTTLE PIVOT BOLT 17. SPRING
3. WASHER 8. JAM NUT 13. CAP SCREW
4. SPECIAL WASHER 9. FRICTION DISC 14. CRANK
5. THROTTLE ROD 10. RUBBER WASHER 15. CLAMP

HAND THROTTLE LEVER

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 9001-5

THROTTLE CONTROL LEVER ADJUSTMENT

Hand Throttle Lever Tension Hand Throttle Adjustment (With

Adjustment Foot Throttle Option)
1. The tension adjusting nut (2) for the throttle lever The adjustment procedure for the hand throttle with
(1) is to compress the rubber washer (10) to the foot throttle option is very similar to the procedure
cause a resistance to hold the throttle lever in the without the foot throttle.
position selected.
1. The tension adjusting nut (2) for the throttle lever
2. The tension adjusting nut (2) is not to be so tight (1) is to compress the rubber washer (10) to
the throttle lever is difficult to move. cause a resistance to hold the throttle lever in the
3. Remove any attachments from the loader lift position selected.
arms. 2. The tension adjusting nut (2) is not to be so tight
4. Refer to the operators manual for the correct the throttle lever is difficult to move.
procedure and tilt the ROPS for service. 3. Remove any attachments from the loader lift
5. The throttle control lever (1) may be in any arms.
working position during the adjustment 4. Refer to the operators manual for the correct
procedure. procedure and tilt the ROPS for service.
6. Measure the resistance that is required to move 5. Disconnect the foot throttle linkage from the
the throttle control lever (1) from the low idle to linkage controller so that the only input to the
high idle position.The effort required to move the controller is from the hand throttle.
throttle control lever (1) should be measured at
6. The throttle control lever (1) may be in any
the top of the throttle control lever (1).
working position during the adjustment
7. Loosen the jam nut (8). procedure.
8. Tighten or loosen the nut (2) until the force 7. Measure the resistance that is required to move
required to move the throttle control lever (1) is the throttle control lever (1) from the low idle to
50 ± 10 N. high idle position.The effort required to move the
9. When the effort required to move the throttle throttle control lever (1) should be measured at
control lever (1) is correct tighten the jam nut (8) the top of the throttle control lever (1).
against the nut (2). 8. Loosen the jam nut (8).
10. Lower the ROPS to the operating position. 9. Tighten or loosen the nut (2) until the force
required to move the throttle control lever (1) is
50 ± 10 N.
10. When the effort required to move the throttle
control lever (1) is correct tighten the jam nut (8)
against the nut (2).
11. Lower the ROPS to the operating position.
12. Depress and release the foot pedal to confirm
proper operation.

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9001-6

4
6
2
5

10
11

12

1
14
13 3

BD05B256
1. BOLT 8. ROD
2. THROTTLE ROD EXTENSION 9. SPRING
3. WASHER 10. ROCKER ARM
4. WASHER 11. BEARING
5. SELF TAPPING SCREW 12. PIVOT SLEEVE
6. SLEEVE 13. BUSHING
7. FOOT THROTTLE PEDAL 14. SQUARE NUT
FOOT THROTTLE LEVER

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 9001-7

CONTROLS ADJUSTMENT PROCEDURE - LOADER FUNCTIONS AND

NEUTRAL POSITION
STEP 1 STEP 4
1 2

BD01J006
BD05B005
1. MEASUREMENT 735 ± 10 MM 1. DIMENSION FOR STANDARD CONTROL HANDLE (25 TO
40 MM)
Center of the seat bar must be 735 ± 10 mm from the 2. DIMENSION FOR DELUXE CONTROL HANDLE (LARGE
bottom surface of the front ROPS cross member HEAD) (15 TO 30 MM)
before making handle position adjustments. If Stroke the both control handles to the Full Forward
measurement is not within the specification, adjust position. With the control handles in any position and
the seat bar to the specifications. See the seat bar hands on the control handles, the control handles or
height adjustment procedure. hands must not contact the front ROPS post or any
front door component (if equipped). The clearance
STEP 2 between the ROPS post and the standard control
Stroke the handles to the Full Reverse position. In handle should be 25 to 40 mm. The clearance
any position the handles must not contact the seat between the ROPS post and the deluxe (large head)
bar. Set the left hand control at 6 to 20 mm clearance control handle should be 55 to 30 mm.
to the seat bar with the handle in the full reverse
If the machine is equipped with side windows there
stroke and in the float position.
should be 25 mm clearance between the control
handles and the side windows when the control
STEP 3 handles are in the locked down position with the seat
NEUTRAL: The front of the top of the handles must bar in the operating (down) position.
be inline with each other by 6 mm. Adjust the Right
Handle position relative to the Left handle.

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9001-8
STEP 5 STEP 2

1 2
1

BD05B007 BD05B004
1. OUTER CONTROL ROD 1. STANDARD HANDLE DIMENSION 15 TO 35 MM
2. DELUXE HANDLE DIMENSION 5 TO 25 MM
Pull the control handle rubber boot up to access the
control linkage. Loosen the jam nuts on the outer
control rod (1) and turn the control rod (1) until the
STEP 3
proper measurement is obtained. Tighten the jam
nuts on the control rod (1). Repeat the same
procedu re fo r th e opposite control handle if
adjustment is required.

Control Handle Fore and Aft

Adjustment
1
STEP 1

BD05B006
1. FORE AND AFT POSITION CONTROL ROD

Pull the control handle rubber boot up to access the

control linkage. Loosen the jam nuts on the fore and
aft position control rod (1) and turn the control rod (1)
until the proper measurement is obtained. Tighten
the jam nuts on the control rod (1). Repeat the same
procedure for the opposite control handle if
adjustment is required.
BD05B003

Make sure the ROPS is in the operating position.

Place a 19.05 mm (0.75 inch) bar through the side
screen on the ROPS in the first row from the front
and five rows up from the bottom as indicated in the
photo above. Slide the bar towards the front of the
machine on both sides until it contacts the ROPS
post on each side of the ROPS as shown in the
photo above.

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 9001-9

Controls - Pump Shim Dimensions STEP 3

The controls should be initially set on the assembly
2 1
using the following shim dimensions. The shim
required for each machine should be used to set the
distance between the tandem pump Tee lever arm
and the pump stop. This should be done for full
forward and full reverse stroke on both the left and
right pumps. The straight tracking screws are the
means to set this gap dimension.

Model Pump Shim (mm) Shim in

Displacement
(in3/ rev
BD05B007
1. JAM NUT
410 2.3 0.90 0.035
2. STRAIGHT TRACKING SET SCREW

420 2.62 0.56 0.022 Pull the control handle rubber boot up to access the
control linkage. Loosen the jam nut (1) on the control
430/440 2.8 0.35 0.014 handle opposite the direction of turn and tighten the
set screw (2) until the machine tracks straight.
Example: If the machine turns to the right, adjust the
tracking set screw (2) on the left control handle.
Tighten the jam nut (1).
Controls Adjustment - Dynamic
STEP 4
Straight Tracking
Repeat step 3 for reverse direction tracking.
NOTE: During the Dynamic Straight Tracking
Adjustment procedure, the adjustments should be STEP 5
made with the hydraulic system at or above 120° F Reinstall the control boot after adjustments are
and in the low speed range of machines equipped complete.
with the two speed option

STEP 1
Install a bucket on the loader lift arms. Drive the
machine forward with both control handles against
the forward stops. The machine should not deviate
more than 6 feet width over 100 feet of forward
travel. If the machine does not meet this requirement
proceed with the following steps.

STEP 2
Drive the machine forward and determine which way
the machine turns.

Bur 6-79500 Issued 2-05 Printed in U.S.A.

9001-10

10
3
12
11

4 5 8
9
12

2
7

BS05B040
1. SEAT BAR LINKAGE 7. BRAKE CAM
2. LOADER LIFT LINKAGE 8. CRANK
3. LOADER TILT LINKAGE 9. LEFT LEVER ASSEMBLY
4. GROUND DRIVE LINKAGE 10. RIGHT LEVER ASSEMBLY
5. BRAKE CONTACT ROD 11. HYDRAULIC BYPASS CABLE
6. PIVOT 12. TRACKING SET SCREW
LOADER AND GROUND DRIVE CONTROL LINKAGE

Bur 6-79500 Issued 2-05 Printed in U.S.A.

 9001-11

13

10

11
12
9

2
6 4 3
5
1

14 7

BS05B041
1. SEAT BAR LINKAGE 8. CRANK
2. LOADER LIFT LINKAGE 9. LEFT LEVER ASSEMBLY
3. LOADER TILT LINKAGE 10. RIGHT LEVER ASSEMBLY
4. GROUND DRIVE LINKAGE 11. HYDRAULIC BYPASS CABLE
5. BRAKE CONTACT ROD 12. SPRING
6. PIVOT 13. PIN
7. BRAKE CAM 14. SEAT BAR CONTROL ROD
LOADER AND GROUND DRIVE CONTROL LINKAGE

Bur 6-79500 Issued 2-05 Printed in U.S.A.

9001-12

SEAT BAR HEIGHT ADJUSTMENT

HS01E003
1. ADJUST TO 735 ± 10 MM (28.93 ± 0.40 IN) 3. LAP BAR
2. ADJUSTING SCREW 4. CROSSMEMBER

1. Measure the distance from the bottom of the 2. Loosen the nut on the adjusting screw (2) on
crossmember (4) of the ROPS frame to the flat each side of the frame and adjust the screw as
spot with the molded seat belt sign on the lap bar needed to obtain the correct measurement.
(3) when the lap bar is in the operating position. Tighten the nuts on the adjusting screws.
This distance (1) must be 735 ± 10 mm (28.93 ±
0.40 in).

Bur 6-79500 Issued 2-05 Printed in U.S.A.

 9001-13

AUXILIARY HYDRAULIC PEDAL

7
3

8 1
2

2
4
1
1

5
2

BS05B060
1. AUXILIARY HYDRAULIC PEDAL 5. CLEVIS
2. AUXILIARY HYDRAULIC PEDAL LOCK LEVER 6. BRACKET
3. LOADER CONTROL VALVE 7. ELECTRICAL HARNESS
4. CONTROL CABLE 8. RELAY

NOTE: Make sure the auxiliary spool in the control valve is in the neutral position. Adjust the cable until the
auxiliary hydraulic pedal is in the horizontal position.

Bur 6-79500 Issued 2-05 Printed in U.S.A.

9001-14
NOTES

Bur 6-79500 Issued 2-05 Printed in U.S.A.

 410 HYDRAULIC SYSTEM 410 LOADER CONTROL VALVE 410 EH VALVE 410 HYDRAULIC COUPLER (OPTION) 410 SECONDARY AUXILIARY (OPTION) 410 SELF-LEVEL (OPTION) 410 RIDE CONTROL (OPTION)
15
Pilot pressure line Pilot pressure line Pilot pressure line Pilot pressure line
Case drain line Case drain line Case drain line Case drain line
P
14 BRAKE
L15

K15 BRAKE 42
T K11
K7B K7A
K5 J5
18 20
K8

17 19
40 FC

44
G6 G7A G7B
J16 J15 J10 K8 46 E9

23 24 A B1 B2 47
H14 J9
H13 11 12 H9
B A L Z Z L B A
13 13 H5
P F7 G8 K11

AUXILIARY OUT 43
16 16 FC FC MC MC R6

30 45
V1 V2
G7B 16 C2 T
5 5 G5 R6 C1 P
G8 G6
G7A A B
MC FC
9 10 A B A B A B
22 INLET P C2 C1 48
F7 FC MC F5 R2
A B INLET CASE DRAIN C D
41 P. B. T
F5
16 30 5 K11
4
R5
A B A B A B R4 HPCO
1 2 E7 E7 K5
F9
6 5 5 8 R2 AUXILIARY 40
E1 E2
16 INLET
FC T P G5
R1 N N R1 5 26 AUX

F1 F2 INLET P
H5
R4 HPCO
45 K8
R1 R1
7 E9 E7
28 27 29 C12
AUXILIARY
3 6 INLET
26
7
25 21 28 27 29
FRAME 1 FRAME 2 FRAME 3 FRAME 4 FRAME 5 FRAME 6 FRAME 7
BC05A008-01A BC05A008-02A BC05A008-03A BC05A008-04A BC05A008-05A BC05A008-06A BC05A008-07A

420 HYDRAULIC SYSTEM 420 LOADER CONTROL VALVE 420 EH VALVE AND HIGH FLOW (OPTION) 420 HYDRAULIC COUPLER (OPTION) 420 SECONDARY AUXILIARY (OPTION) 420 SELF-LEVEL (OPTION) 420 RIDE CONTROL (OPTION)
15
Pilot pressure line Pilot pressure line Pilot pressure line Pilot pressure line
Case drain line Case drain line Case drain line Case drain line
P
14 BRAKE
L15

K15 BRAKE F9 42
T K11
K7B K7A

18 20
K5 J5 38
E 37 K7B K7A
K8
P

17 19 SV1
39
40 FC
CV1
44 RV1

R3 G6 G7A G7B
J16 J15 J10
AUX T
K8 46 E9

23 24
J5 A B1 B2 47
H14 J9
H13 11 12 H9
B A L Z Z L B A
13 13 H5
P F7 G8 K11

AUXILIARY OUT 43
16 16 FC FC MC MC R6

30 45
V1 V2
G7B 16 C2 T
5 5 G5 R6 C1 P
G8 G6
G7A A B
MC FC
9 10 A B A B A B
22 INLET P C2 C1 48
F7 FC MC F5 R2
A B INLET CASE DRAIN C D
41 P. B. T
F5
16 30 5 K11
4
R5
A B A B A B R4 HPCO
1 2 E7 E7 K5
F9
6 5 5 8 R2 AUXILIARY 40
E1 E2
16 INLET
FC T P G5
R1 N N R1 5 26
AUX

F1 F2 INLET P
H5
R4 HPCO
45 K8
R1 R1
7 E9 E7
28 27 29 C12
AUXILIARY
3 6 INLET
26
7
25 21 28 27 29
FRAME 1 FRAME 2 FRAME 3 FRAME 4 FRAME 5 FRAME 6 FRAME 7
BC05A008-11A BC05A008-12A BC05A008-13A BC05A008-14A BC05A008-15A BC05A008-16A BC05A008-17A

COMPONENT IDENTIFICATION

1. LEFT PISTON PUMP 40. ATTACHMENT CASE DRAIN

2. RIGHT PISTON PUMP 41. HYDRAULIC COUPLER CONTROL VALVE
3. CHARGE PUMP 42. HYDRAULIC COUPLER CYLINDER
4. HYDROSTATIC PUMP 43. SECONDARY AUXILIARY CONTROL VALVE
5. CIRCUIT RELIEF VALVE 44. 100 MESH SCREEN
6. TOW VALVE 45. ACCUMULATOR
7. CHECK VALVE 46. CHECK VALVE
8. HYDRAULIC PUMP 47. SELF-LEVEL VALVE
9. LEFT DRIVE MOTOR 48. RIDE CONTROL SOLENOID VALVE
10. RIGHT DRIVE MOTOR
11. LEFT BRAKE
12. RIGHT BRAKE
13. FLUSHING VALVE
14. BRAKE SOLENOID VALVE
15. CHARGE PRESSURE SWITCH
16. ORIFICE
17. HYDRAULIC RESERVOIR
18. DRAIN MANIFOLD
19. OIL COOLER
20. OIL COOLER BYPASS VALVE
21. BACKUP ALARM SWITCH PORTS
22. BRAKE LIGHT SWITCH PORTS
23. TILT CYLINDERS
24. LIFT CYLINDERS
25. MAIN RELIEF VALVE
26. LOADER CONTROL VALVE
27. TILT SPOOL
28. LIFT SPOOL
29. AUXILIARY SPOOL
30. AUXILIARY OUTLETS
31. NOT USED
32. NOT USED
33. NOT USED
34. NOT USED
35. NOT USED
36. NOT USED
37. HIGH FLOW PUMP
38. HIGH FLOW OIL COOLER
39. HIGH FLOW CONTROL VALVE

NOTES HYDRAULIC SYMBOLS

410 RELIEF VALVE PRESSURES
R1 = 4350 PSI (300 BAR)
420 RELIEF VALVE PRESSURES
R1 = 4060 PSI (280 BAR)
TEXT LEGEND
FC = FEMALE CONNECTOR PRESSURE HYDRAULIC SCHEMATIC
R2 = 3350 PSI (231 BAR) R2 = 3350 PSI (231 BAR) MC = MALE CONNECTOR PILOT PRESSURE 54 CHECK VALVE FILTER OR SCREEN 410, 420 SKID STEER AND 420CT COMPACT TRACK LOADER
R3 = 3250 PSI (224 BAR) R3 = 3250 PSI (224 BAR) Additional copies of this Hydraulic and Electrical Schematic can be ordered through Technical Publications Distribution System.
R4 = 3050 PSI (210 BAR) R4 = 3050 PSI (210 BAR) CASE DRAIN COMPONENT SHOWS CIRCUIT SHOWS The part number is 6-78971
R5 = 2500 PSI (186 BAR) R5 = 2500 PSI (186 BAR) NUMBER CROSSING CIRCUIT
COMPONENT RESTRICTOR
R6 = 1900 PSI (131 BAR) R6 = 1900 PSI (131 BAR) NOT CONNECTED CONNECTED OIL COOLER
BC05A008-00A
 STARTING SYSTEM POWER DISTRIBUTION FUEL SUPPLY SYSTEM ENGINE PRE-HEAT SYSTEM SAFETY INTERLOCK SYSTEM INSTRUMENT CLUSTER STANDARD LAMPS HORN (OPTIONAL) BACK-UP ALARM (OPTIONAL) FRONT DOOR (OPTIONAL)

780A R-3.0 2
6 180A R-5.0 180A R-5.0 130C R-0.5 1
40A 782A P-0.5 6
190A R-5.0 190A R-5.0 300A R-2.0
50 2 300G R-0.5 300G R-0.5
137B R-0.8

WASHER
4 131A R-1.0 131A R-1.0 300B R-2.0 300E R-1.0 300H R-0.5 300H R-0.5 1 781A P-0.5 6 4 7

WIPER
40A 141

20 21 170A R-5.0 EMPTY 32

781A P-0.5

131C R-1.0
A B 25 86 30 18 7 A OFF ON ON
OCCUPIED 783E P-2.0 783F P-1.0
15A
20 B 37 48A
10 UP
137H R-1.0
137K R-1.0

130A R-2.0
121A Y-1.0

8 B1 E1 H1 A2

137D R-1.0
782A P-0.5

837A W-1.0
835A O-1.0
783G P-1.0
622D W-1.0 5
641A W-1.0 6
18
DOWN
59A 59
19 INSTRUMENT CLUSTER 7 8A B1 E1 H1 A2
120B R-8.0 BAT V+ (IN) 3
602G W-1.0 5 NC NC- R-1.0 C C
IGN ON (IN) 24
86 30 7 86 30 64 641A W-1.0

300D R-1.0
86 30 14

303D T-1.0
COM NO- W-1.0 B B 4 34

783D P-2.0
9 B A 58 IGN ON (IN) 23 3 8 141

781B P-0.8
NO COM- B-1.0 A A ACC ON / IGN OFF (IN) 10 A
160A R-8.0
8 52
1 18 85 87 87A 130E R-0.8 1 START (IN) 11 B 38

300E R-1.0
6

323A T-0.5
2.4 W 261A Y-1.0

830D R-2.0
830E R-1.0

830F R-2.0
6 52A ROAD LIGHTS (OUT) 21
7 9 8 10 52
7 9 8 10 52A
COIL
16 12 WORK LIGHTS (OUT) 22
8 8A

625A W-3.0
DOOR OPEN
641B W-0.5 D3 D3 24

178E B-1.0
PREHEAT (OUT) 7

178R B-1.0
178X B-1.0
602C W-1.0
817F R-2.0 DOOR CLOSED
5 18 8A 23 INSTRUMENT CLUSTER
HYD FILTER LAMP 15 261B Y-0.5 G2 G2
27 48 51A 51
625B W-3.0

15A HYD OIL TEMP LAMP 264B Y-0.5 G4 G4 264A Y-1.0

131E R-1.0

2
121C Y-1.0

7 85 87 87A 14 85 87 87A 64 85 87 87A

817A R-1.0 14 55 D2 D2 12 SEAT SWITCH (IN) ENGINE COOLANT TEMP LAMP 25 257B Y-0.5 G1 G1 257A Y-1.0 NC NC- R-1.0 C C
1 2
C2 C2 303C T-0.8 313D T-0.8 14 INTERLOCKV+ (OUT) AIR FILTER LAMP 16 266B Y-0.5 J1 J1 266A Y-1.0
P A B 99 COM NO- W-1.0 B B
1 101
178B B-1.0 178B B-1.0 138A R-5.0 3 4 820A R-2.0 16 258B T-1.0 D4 D4 258C T-0.5 8 PARK BRAKE (OUT) FUEL SENDER SIGNAL 1 234B Y-0.5 F1 F1 234A Y-1.0 2 101A NO COM- B-1.0 A A
10A 311B P-1.0 H2 H2 311C T-1.0 A A 5 FUEL SOLENOID (OUT) ENGINE OIL PRESS LAMP 18 255B Y-0.5 E4 E4 255A Y-1.0 21

178AH B-1.0
16

136A R-5.0
751F R-1.0 311F T-1.0 C1 C1 42
311D T-1.0 50J 311J T-1.0 262A Y-0.5
105 B A 137H R-1.0 137H R-1.0 17 B B 26 AUX HYD OVERRIDE (OUT) CHARGE PRESS LAMP 17 G3 G3

780A R-3.0

782C P-0.8

781C P-0.8
782B P-0.8
5 6 50

783C P-2.0
101B 1 102 1
2 L R 130A R-2.0 137C R-3.0 137C R-3.0
10A 602A W-1.0 J2 J2 602B W-0.5 13 23
34 P
895A O-1.0 2
131A R-1.0

178E B-1.0
751D R-1.0 319B T-1.0 D1 D1 319A T-0.5 6 33 895B O-1.0
17A A B 7 8 11 264A Y-1.0 890A R-1.0 8 8A

313G T-1.0
313H T-1.0
4 TURN INDICATOR A 2 43
B+ G
17 A B
540B R-1.0 15
8
8 8A B 39 45 K2 K2 830A R-3.0 2
P 622A W-1.0 5 754A P-0.5 B4 B4 124C R-1.0
17 21
4 A1 B2 A3 B3 8A
540C R-1.0 13 15 TACHOMETER 19 124B R-0.5 J3 J3 28
783B P-2.0
39

706D P-3.0
784B P-2.0

784A P-1.0
A1 B2 A3 B3 8 178CC B-1.0 127

643A R-8.0
9 F4 F4 A
124A R-1.0 602A W-1.0 A A 602G W-1.0

783A P-3.0
6 3 CLEAN GROUND 20 200C B/W-0.5 K1 K1 96 86 30 93 86 30 J4 J4 892C O-1.0 B 25
15

830B R-3.0
B B 44 178WH B-1.0
622B W-1.0
130B R-2.0
131B R-1.0
137A R-3.0

120A R-8.0 319D T-1.0 C C 622D W-1.0 1 23 1 2 3 4 5 52 8 8A 1 178WG B-1.0

895A O-1.0 P
9 D D 1 2 3 4 5 52A
35 36 897A O-1.0
2 835B 0-1.0

137E R-1.0
160A R-8.0 8 10A 7 127A 200D B/W-1.0 35
120B R-8.0

4 45 113
890A R-1.0 8 622A W-1.0 706B P-1.0
625B W-3.0

6 15A 5
1 46 140 140A
300A R-2.0 79 36 40 A 313F T-1.0 1 1 313G T-1.0
50A 4 130C R-0.5 6 4 25A 3
5
319C T-1.0 A
262B Y-1.0 124A R-1.0 1 40 B 313J T-1.0 2 2 313H T-1.0 112 112A

706A P-3.0
24 96 85 87 87A 93 85 87 87A
136A R-5.0 830A R-3.0 10 565A T-1.0 B 892A O-1.0 50A 3 3 835A O-1.0 1 1
130E R-0.8 5 2 20A 1 178M B-1.0 4 4 2 2
234A Y-1.0 257C Y-1.0
130D R-2.0

137F R-3.0 610A W-1.0 610A W-1.0 41 A A 830C R-2.0 5 5 830D R-2.0 830F R-2.0 3 3

178W B-1.0
706C P-1.0
178F B-1.0
120C R-8.0 2 258B T-1.0 897A O-1.0 B B 178WH B-1.0 6 6 178WP B-1.0 178WP B-1.0 4 4
178AU B-0.8
POS_CBL

61
780A R-3.0 7 311F T-1.0 255C Y-1.0 65 65A
137B R-0.8 6 14 2 1 80 A B 48 27 44 178N B-1.0
C B D A 9 11 17 31 28 266C Y-1.0 26 38 140B
M 22 57 1
B 311G T-1.0 CONNECT TO 140 2 313JP T-1.0
A
SPL14
24 25 37 41 WHEN DOOR IS 3
ACC B 2 P 4
IGN P V 1
REMOVED
A 5
1 3 ST
B 311H T-1.0
12 29 6

178E B-1.0
A 30

47

178BC B-1.0
178BD B-1.0

200D B/W-1.0
178CH B-1.0
178CJ B-1.0
103

178AH B-1.0

178AC B-1.0
178AE B-8.0

178CK B-1.0
178A B-2.0

178E B-1.0

178K B-1.0

178M B-1.0
178R B-1.0

178N B-1.0
178X B-1.0

178T B-3.0
23

178L B-2.0
178G B-1.0
178H B-1.0

178U B-0.8
7 33 30
32 29
NEG_CBL

FRAME 1 FRAME 2 FRAME 3 FRAME 4 FRAME 5 FRAME 6 FRAME 7 FRAME 8 FRAME 9 FRAME 10
BC04M092-01A BC04M092-02A BC04M092-03A BC04M092-04A BC04M092-05A BC04M092-06A BC04M092-07A BC04M092-08A BC04M092-09A BC04M092-10A

HIGH FLOW ELECTRO-HYDRAULIC RIDE CONTROL (OPTIONAL) ROTATING BEACON (OPTIONAL) ELECTRICAL ACCESSORY OUTLET HYDRAULIC COUPLER DOME LIGHT/HEATER (OPTIONAL) TURN SIGNALS (OPTIONAL) LOADER ARM AUXILIARY ELECTRIC (OPTIONAL) AUXILIARY OVERIDE SYSTEM HAZARD SWITCH AND FLASHER HARNESS (OPTIONAL)
ATTACHMENT FLOW (OPTIONAL) (OPTIONAL) (OPTIONAL)

70 540G R-1.0
70A 70 13 69
535B T-1.0 V V 535A T-1.0 540A R-1.0 S S 540B R-1.0 2 B B
547A T-1.0 C C A A
TO DOME LAMP LIFT ARM CONNECTOR
751D R-1.0 U U 13 178Z B-1.0
49 T T
69A 107 E F K G H C D J B A L M N P
SPL
A 72 P P 66B 66C
604A W-1.0 #F3
70A A 757FB P-1.0 757FA P-1.0 A

70A
B 759FA P-1.0 751FA R-1.0 B
CONNECT TO 127 5 127B 127C 5 CONNECT TO 127A
C 756FB P-1.0 756FA P-1.0 C
178AF B-1.0 820B R-2.0 B B 820A R-2.0 SPL SPL

002B DB-1.0

178JH B-2.0
2 D 759FB P-1.0 D

008B W-1.0
17

004B R-1.0
001B B-1.0

006B P-1.0
817J O-2.0

005B Y-1.0

007B T-1.0
A A #F2 #F1
547B T-1.0 70 E 758FA P-1.0 E 17
B B CONNECT TO 66
B A 115
F 754FA P-1.0 F CONNECT TO 66A
B C 72 C C
B A 115A OFF G G
D D
751E R-1.0 178CG B-0.8 ON
H 178FA B-1.0 H

602D W-1.0
62 64

756FC P-1.0

757FC P-1.0
756FD P-1.0

757FD P-1.0
178BA B-1.0

758FA P-1.0

754FA P-1.0
547D T-1.0
56 ET001C R-0.8 L
RD
A
85
751D R-1.0 2 B M
BL 757B P-1.0 A
B A 68A B
BK 172 751G R-1.0 B 602F W-1.0
B A 68 C H C 24
3 2 170 756B P-1.0 C
1 2 3 4 5 6 7 8 9 10 11 12 138

SPOOL ENGAGED
SPOOL NEUTRAL
77 178BB B-0.8 171 171 172

622D W-1.0
602E W-1.0

319E T-1.0
766A P-1.0 1 2 3 4 5 6 7 8 9 10 11 12 138A 276 A B C D E F
A 548B T-1.0 B 547E B-0.8
1 2 81 24 A 26 71A ET007A R-1.0
B 55 D 67 A B 73

178HJ B-2.0
1 2 81B

817H O-2.0
ET006A Y-0.8
CONNECT B 817D R-1.0 1 2 76 61 75

ET001A R-2.0
123
178BZ B-1.0
A
74

ET000D B-1.0
ET000E B-0.8
TO 71
178DA B-1.0 66 86
275
TO ACCESSORY A A 757A P-1.0 A A
30
1 170 B B 751F R-1.0 B B 85 GRD
POWER OUTLET 21 178FA B-1.0
78 (EUROPE) 58 59 C C 756A P-1.0 C 150 130
751FA R-1.0
85
86 86 BATT

70A 70 E A 67 ET000E B-0.8

D
E
D
E
759A P-1.0
758B P-1.0
2 817F R-2.0 A A 69 320B LB-1.0 319F T-1.0 759FC P-1.0 87
87 LOAD
B B 87A
178DC B-1.0
178BD B-1.0

F A B 129
540C R-1.0 A A 540F R-1.0 F 754C P-1.0
178DD-1.0
545B T-1.0

546B T-1.0

751F R-1.0 150A

54 2

320A LB-1.0
ET000D B-1.0 G G 2
H H
540G R-1.0 49
178DE B-1.0

16 ET003A P-2.0 E E ET003C P-2.0

817G O-2.0
70A 66A
535D T-1.0
535C T-1.0

71 547A T-1.0 117 B B 759A P-1.0 20 008A W-1.0 8

ET001A R-2.0 ET004A Y-2.0 ET004C Y-2.0
A B 120 1 2 121 1 2 122
16 178Z B-1.0 2 817A R-1.0 R R 817B R-1.0
178AD B-1.0
B
A UNLATCH
B B ET001B R-0.8 ET005A O-2.0 C C ET005C O-2.0 007A T-1.0 7
6
72
A 75 A A ET000A B-2.0 ET000C B-1.0 D D ET000H B-2.0 006A P-1.0
LATCH

70 D 92
117A ET000B R-0.8 ET008A LB-1.0 A A 758B P-1.0 20 005A Y-1.0 5
4 25 86 30 125 86 30 128 17 758B P-1.0 70A 70
TO ACCESSORY ET009A LB-1.0 F F 004A R-1.0
POWER OUTLET 177 178 179 003D O-1.0 3
A B 124
(10 AMP MAXIMUM)
57 183
1
174 175
754C P-1.0 002A DB-1.0 2
K K
L L
758A P-1.0
759B P-1.0 73
21

ET0009C LB-1.0

ET008C LB-1.0
(NORTH AMERICA) 1 001A B-1.0 1
183A 70 71 17 759A P-1.0
184

ET010A LB-1.0
B D 75 SPL 15 E A 92
M
50 51 52 53 176 F E D C B A
65
540A R-1.0 VALVE CONNECTOR 125 85 87 87A 128 85 87 87A

ET011A LB-1.0
P 186
182
63 1
180 624A DB-1.0

178DF B-1.0
67 T
185 178DG B-1.0 604A W-1.0
178BCF B-1.0

178AG B-1.0
178AN B-1.0
178BF B-0.8

178AF B-1.0

178AL B-0.8
178CE B-20

178BJ B-2.0
178CG B-0.8

178AD B-1.0
178AJ B-0.8

178Y B-1.0

181
66

FRAME 11 FRAME 12 FRAME 13 FRAME 14 FRAME 15 FRAME 16 FRAME 17 FRAME 18 FRAME 19 FRAME 20
BC04M092-11A BC04M092-12A BC04M092-13A BC04M092-14A BC04M092-15A BC04M092-16A BC04M092-17A BC04M092-18A BC04M092-19A BC04M092-20A

LIGHTING (OPTIONAL) LOADER LOCK OUT (OPTIONAL) EURO ON ROAD BRAKE LIGHTS LEFT-HAND HANDLE (OPTIONS) RIGHT-HAND HANDLE (OPTIONS) LEGEND
1. BATTERY 39. REAR WORKLIGHT 78. LEFT FRONT TURN LIGHT
70

754B P-1.0 N N 754C P-1.0 OPTION F OPTION G 2. ALTERNATOR 40. LEFT REAR INDICATOR LIGHT 79. RIGHT FRONT TURN LIGHT
17
70A OPTION A OPTION B 3. STARTER AND SOLENOID 41. RIGHT REAR INDICATOR LIGHT 80. LEFT FRONT POSITION LIGHT
97 85A 123B
A A C 756AA LB-0.8 A 545AB Y-1.0 545BB Y-0.8
4. CIRCUIT BREAKER 42. NOT USED 81. RIGHT FRONT POSITION LIGHT
754B P-1.0 B B 754A P-0.5 5 17
B 11 B 546AB LB-1.0 92 93 5. STARTER RELAY 43. NOT USED 82. LICENSE PLATE LIGHT
97A A 757AA Y-0.8 92 6. RESISTOR (50 OHMS) 44. HORN 83. RESISTOR
90 91 98
226
39G
7. IGNITION SWITCH 45. BACKUP ALARM SWITCH (LEFT) 84. LOADER LOCKOUT SWITCH
RIGHT
LEFT

76 890AG R-1.0 890BG R-0.8

FWD

A
REV

OFF

178TB B-1.0 1 1 B
8. MAIN POWER RELAY 46. BACKUP ALARM SWITCH (RIGHT) (OPTIONAL)
ON

8 B 892AG V-1.0
706TB P-1.0 2 2 R 39F
701TA P-1.0 3 3 DG 71B
A 890AF R-1.0
9. OPTIONS POWER RELAY 47. BACKUP ALARM 85. NOT USED
B 548AG V-1.0
756TB P-1.0 4
226A
4 LG
83 14
B
A
700B P-1.0
178EB B-1.0
8 B 892AF V-1.0 12 A 10. DIODE (REVERSE POLARITY) 48. CAB DOOR SWITCH 86. LEFT BRAKE LIGHT SWITCH
79B
CONNECTS 540AA O-0.8 B 311CB R-0.8
77G 11. PRIMARY FUSE BLOCK 48A. WIPER/WASHER SWITCH (EURO)
TO 71 5 A 311AB R-1.0
OPTION H 12. OPTIONS FUSE BLOCK 49. ELECTRO HYDRAULIC HIGH 87. RIGHT BRAKE LIGHT SWITCH
60 71C 700B P-1.0 GRD 4 13. NOT USED FLOW SWITCH (EURO)
B 700A P-1.0
86B 228 14 A 178EB B-1.0 OPTION C 14. FUEL PUMP 50. DIODE 88. BRAKE LIGHT TIMER RELAY
EXTEND RETRACT
C 757TC P-1.0 178TA B-1.0 2 2 B 78 CONNECTS 178EA B-1.0 (UP) (DWN) 15. FUEL HOLD-IN SOLENOID 51. COMBINATION SOLENOID (EURO)
B 178TE B-1.0 706TA P-1.0 TO 71A
17
A 756TC P-1.0 756TA P-1.0
4
3
4
3
R
LG
123C
92 93 FRT. ELECT
16. COIL 52. FORWARD SOLENOID 89. OPTION NOT AVAILABLE 410,420
A 545AC Y-1.0 545BC Y-0.8
SPL_T1 706TH P-1.0 1 1 RLB 80 11 B 546AC LB-1.0
CTRL SW. #1 17. GLOW PLUGS 53. REVERSE SOLENOID 90. TURN SIGNAL SWITCH
706TA P-1.0 228A 704A P-1.0 70
39H 18. INTERLOCK RELAY 54. RIDE CONTROL SOLENOID 91. ATTACHMENT HYDRAULIC
84 91 98 178AK B-3.0 E E 178AM B-3.0
19. SEAT SWITCH 55. ROTATING BEACON SWITCH SWITCH
F 119
8
A
B
890AH R-1.0
892AH V-1.0
890BH R-0.8 94 70A GRD 2
89
FWD

178TD B-1.0 20. SEAT BAR SWITCH 56. ROTATING BEACON 92. HORN SWITCH
86 87
REV

OFF

ON

SPL_T6 LOCKED FREE

SPL_T5
B 548AH V-1.0 21. NOT USED 57. HYDRAULIC COUPLER SWITCH 93. RIDE CONTROL SWITCH
P P 12 A
7 706TD P-3.0 706TC P-1.0 230 77H
EXTEND RETRACT
(UP) (DWN)
22. LOADER VALVE SOLENOID 58. DIODE 94. FRONT ELECTRIC CONTROL
SPL_T3
102B A A R 82 79C 8 23. LOADER VALVE SOLENOID 59. HYDRAULIC COUPLER RELEASE SWITCH No. 1

178AB B-3.0
SPL7
178TC B-1.0 B B B 119 E
B 565AC T-0.8 311BC R-0.8 311CC R-0.8 178V B-5.0 K3 K3 178S B-5.0
230A 5 A 311AC R-1.0 49H 24. BRAKE RELEASE/TANDEM PUMP SOLENOID 95. FRONT ELECTRIC CONTROL
1 001 B-0.8 8A SPL5
701A P-1.0 700A P-1.0 2 002 DB-0.8
FRT. ELECT
178CL B-1.0 178J B-2.0 NEUTRAL OVERRIDE SOLENOID 60. LEFT-HAND FRONT HEADLAMP SWITCH No. 2
CTRL SW. #2
25 701TA P-1.0
50C 50D 3 003 O-0.8 SPL12 GRD 1 25. OPTION NOT AVAILABLE 410,420 61. HEAT CONTROL SWITCH 96. FRONT ELECTRIC CONTROL
250A 701TB P-1.0 A 12B T-1.0 13B T-1.0 A 190 87 4 004 R-0.8
003A O-0.8 95 26. NOT USED 62. FAN SPEED SWITCH SWITCH No. 3
B 13A T-1.0 B 18
706TE P-2.0

5 005 Y-0.8
88

178CM B-2.0
178CN B-2.0
6 006 P-0.8 27. HYDRAULIC FILTER PRESSURE 63. BLOWER MOTOR 97. FRONT ELECTRIC CONTROL
757TC P-1.0

OPTION D SPL11
178TF B-1.0

7 007 T-0.8
T 85D 8 008 W-0.8 EXTEND RETRACT SWITCH 64. OPTION NOT AVAILABLE 410,420 SWITCH No. 4
68 C 756AD LB-0.8 (UP) (DWN)
28. HYDRAULIC OIL TEMPERATURE 65. OPTION NOT AVAILABLE 410,420 98. ATTACHMENT HYDRAULIC
B 540AD O-0.8 SPL25 SPL24
229 17
A 757AD Y-0.8 SENDER 66. OPTION NOT AVAILABLE 410,420 FORWARD FLOW "ON" SWITCH
SPL_T7 178TH B-1.0 2 2 B 79 190 85 86
706TG P-1.0 4 4 R 123D
FRT. ELECT
29. ENGINE COOLANT 67. OPTION NOT AVAILABLE 410,420
757TA P-1.0 3 3 LG START
250 A 545AD Y-1.0 545BD Y-0.8 CTRL SW. #3 TEMPERATURE SENDER 68. RIGHT-HAND FRONT HEADLAMP
SPL_T2 706TJ P-1.0 1 1 RLB 81 11 546AD LB-1.0 GRD
RIGHT

B
178EA B-1.0 702A P-1.0 003B O-0.8 96
LEFT

SPL_T4 706TG P-1.0 229A

21 30. AIR FILTER RESTRICTION 69. AUXILIARY HYDRAULIC NEUTRAL
91 98 SWITCH SPOOL SWITCH
227
89 31. FUEL SENDER 70. STARTING INTERLOCK RELAY
FWD
REV

OFF

ON

178TG B-1.0 1 1 B 77 ON OFF

32. ENGINE OIL PRESSURE SWITCH 71. FUEL SOLENOID RELAY
706TF P-1.0 2 2 R

200D B\W-1.0
701TB P-1.0 3 3 DG 33. CHARGE PRESSURE SWITCH 72. DIODE

178CH B-1.0

178CC B-1.0
178BD B-1.0

178BC B-1.0

178CK B-1.0

187AC B-1.0
178AH B-1.0
178CE B-2.0

178CG B-0.8
178AG B-1.0
178AN B-1.0

178AD B-1.0
178AF B-1.0
178BJ B-2.0

178BF B-0.8

178CJ B-1.0
178AL B-0.8
178AE B-8.0

178CF B-1.0

178AJ B-0.8
90

178U B-0.8
178H B-1.0

178N B-1.0
178M B-1.0

178X B-1.0

178K B-1.0

178A B-2.0
178G B-1.0

178R B-1.0
178Y B-1.0

178T B-3.0

178L B-2.0
757TB P-1.0

NEG CBL
4 4 LG
227A
83 79D FRT. ELECT 34. DIODE 73. HAZARD SWITCH
B 565AD T-0.8 311BD R-0.8 311CD R-0.8 CTRL SW. #4
5 A 311AD R-1.0 003C O-0.8 97 35. LIGHT RELAY No. 1 74. FLASHER MODULE
36. LIGHT RELAY No. 2 75. DIODE PACK
37. LEFT FRONT WORKLIGHT 76. LEFT REAR TURN LIGHT
FRAME 21 FRAME 22 FRAME 23 FRAME 24 FRAME 25 FRAME 26 38. RIGHT FRONT WORKLIGHT 77. RIGHT REAR TURN LIGHT
BC04M092-21A BC04M092-22A BC04M092-23A BC04M092-24A BC04M092-25A BC04M092-26A

CIRCUIT DIAGRAM LEGEND WIRE IDENTIFICATION NOTES

702A P-1.0
INDICATES WIRE NUMBER
ELECTRICAL SCHEMATIC
INDICATES WIRE SIZE
23 MALE
TERMINAL
FEMALE
TERMINAL EXTERNAL
INTERNALLY
GROUNDED
WIRE COLOR
410, 420 SKID STEER AND 420CT COMPACT TRACK LOADER
54 30 8 NUMBERS REFER TO THE GROUND Additional copies of this Hydraulic and Electrical Schematic can be ordered through Technical Publications Distribution System.
COMPONENT B . . BLACK LB . LIGHT BLUE P . . PURPLE
SHOWS CIRCUIT SHOWS FRAME NUMBER AT THE The part number is 6-78971
CROSSING CIRCUIT COMPONENT WIRE TAG CONNECTOR BOTTOM CENTER OF B/W BLACK/WHITE O . . ORANGE R . . RED
GROUND
NOT CONNECTED CONNECTED NUMBER NUMBER NUMBER EACH FRAME.
BC04M092-00A